OPERATION, SERVICE & PARTS MANUALBefore installing hoist, fill in the information below. Refer to the Hoist and Motor data plates. Model No._____________________ Serial No.______________________ Purchase Date_ ________________ Voltage________________________ Rated Load____________________ SHAW-BOX ™ ® WORLD SERIES WIRE ROPE HOISTS RATED LOADS THRU 15 METRIC TONNE Follow all instructions and warnings for inspecting, maintaining, and operating this hoist. The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper instructions and warnings are not followed. Before using this hoist, each operator should become thoroughly familiar with all warnings, instructions, and recommendations in this manual. Retain this manual for future reference and use. Forward this manual to operator. Failure to operate equipment as directed in manual may cause injury. division of Columbus McKinnon Corporation YALE LIFT-TECH SHAW-BOX ® February, 2009 Copyright 2009, YaleLift-Tech, division of Columbus McKinnon Corporation Part No. 113533-98 FOREWORD This manual contains important information to help you install, operate, maintain and service your new SHAW-BOX electric hoist. We recommend that you study its contents thoroughly before putting the hoist into use. We also recommend that you read Section IX - Series Lifting Equipment of the European Federation of Materials Handling and Storage Equipment (FEM) and the applicable performance and safety standards referenced therein. Then, through proper installation, application of correct operating procedures, and by practicing the recommended maintenance procedures, you can expect maximum lifting service from the hoist. It will likely be a long time before parts information found in the Parts List is needed. Therefore, after the hoist is installed and you have completely familiarized yourself with operation and preventative maintenance procedures, we suggest that this book be carefully filed for future reference. When ordering replacement parts from this book, it will be necessary that you include with your order: the Hoist Serial Number and Model Number that are found on the nameplate attached to the hoist as shown in Figure 4-1. For your convenience, a space has been provided on the front cover of this Manual for entering this information. We recommend that you fill it out immediately so it is readily at hand when needed. The contents of this manual are of necessity, general in nature and may cover features not incorporated on your hoist; or, you may have ordered features not covered by this manual. Therefore, the user must exercise care in applying instructions given in this manual. If specific information not in this manual is required, contact the factory. THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND YALE LIFT-TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT YALE LIFT-TECH MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN THIS MANUAL. NOTICE: Information contained in this book is subject to change without notice. INDEX SECTION I Paragraph Paragraph Paragraph SECTION II Paragraph Paragraph Paragraph Paragraph SECTION III Paragraph Paragraph Paragraph SECTION IV Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph SECTION V Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph SECTION Vl SECTION Vll Paragraph Paragraph Paragraph Paragraph Paragraph SECTION IX Paragraph Paragraph GENERAL DESCRIPTION Page 1-1 General. ................................................................................................................................................................................. 3 1-2 Basic Construction............................................................................................................................................................... 3 1-3 Selection & Application Guide.............................................................................................................................................. 3 INSTALLATION 2-1 General. ................................................................................................................................................................................. 4 2-2 Installing Hoist...................................................................................................................................................................... 4 2-3 Connecting Hoist to Electrical Service................................................................................................................................. 5 2-4 Pre-Operational Checks....................................................................................................................................................... 5 OPERATION 3-1 General. ................................................................................................................................................................................. 6 3-2 Push Button Operation......................................................................................................................................................... 6 3-3 Operating Precautions.......................................................................................................................................................... 6 LUBRICATION 4-1 General. ................................................................................................................................................................................. 7 4-2 Changing Gear Case Oil....................................................................................................................................................... 7 4-3 Lubrication of Hoist Cable.................................................................................................................................................... 8 4-4 Lubrication of Limit Switch................................................................................................................................................... 8 4-5 Lubrication of Geared Trolley Wheels and Pinions............................................................................................................... 8 4-6 Lubrication of Rope Guide. ................................................................................................................................................... 8 4-7 Lubricant Specifications....................................................................................................................................................... 9 INSPECTION AND PREVENTIVE MAINTENANCE 5-1 General .............................................................................................................................................................................. 10 5-2 Inspection Lower Block...................................................................................................................................................... 13 5-3 Inspection Upper Block...................................................................................................................................................... 13 5-4 Inspection Electrical Controls............................................................................................................................................. 13 5-5 Inspection of Rope Guide................................................................................................................................................... 13 5-6 Rope Inspection, Replacement & Maintenance................................................................................................................. 14 5-7 Rope Reeving..................................................................................................................................................................... 15 5-8 Inspection of Rope Drum & Shaft....................................................................................................................................... 17 5-9 Inspection of Hoist Gearing................................................................................................................................................ 17 5-10 Inspection of Motor Brake & Actuating Mechanism........................................................................................................... 18 5-11 Inspection of Traverse Drive............................................................................................................................................... 21 5-12 Testing Block Operated Limit Switch . .............................................................................................................................. 22 5-13 Testing Over-Capacity Limit Switch.................................................................................................................................... 22 5-14 Testing Hoist....................................................................................................................................................................... 22 TROUBLESHOOTING................................................................................................................................................................... 22 ADJUSTMENTS 7-1 Motor Brake Adjustment. .................................................................................................................................................... 24 7-2 Block Operated Limit Switch Adjustment. .......................................................................................................................... 24 7-3 Geared Rotary Limit Switch Adjustment. ............................................................................................................................ 24 7-4 Over-Capacity Limit Switch Adjustment............................................................................................................................. 25 7-5 Shortening of Push Button Station..................................................................................................................................... 25 PARTS LIST 9-1 General. ............................................................................................................................................................................... 28 9-2 List of Parts Illustrations..................................................................................................................................................... 28 SECTION VIII WIRING DIAGRAMS.....................................................................................................................................................................25-27 No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Page 2 SECTION I - GENERAL DESCRIPTION 1-1. GENERAL. SHAW-BOX "World Series" electric hoists are wire rope and drum type hoists that are manufactured with an integral trolley. These hoists are all low headroom models with the rope drum and upper block supported on opposite sides of the beam, by the trolley frame. There are three basic frame sizes, each with two standard lifts. The "B" Frame handles capacities up to 5 tonne, the "C" Frame handles up to 10 tonne and the "D" Frame handles up to 15 tonne. The "B" Frame has an integral trolley with three different flange width ranges available: 4 5/8" through 8", 8-1/8" through 14" and 14-1/8" through 20" with a maximum flange thickness of 1-5/8". The "C" Frame integral trolley has a flange width range of 6" through 20", with the same range breaks and flange thickness allowance as the "B" Frame above. The "D" Frame integral trolley has a flange width range of 8" through 14" and 14-1/8" through 20" with a maximum flange thickness of 1-3/4". The hoist motor is 2-speed with a 4:1 ratio between high and low speeds, as standard. The motor driven trolley has two available speeds with 1, 2 speed, or variable frequency control. Throughout this manual, you will see references to the "B", "C" or "D" Frame hoists. If you are unsure about which frame size you have, see Section IV, Paragraph 4-2 for a simple gearcase measurement to easily determine the size of your hoist. 1-2. BASIC CONSTRUCTION. SHAW-BOX "World Series" hoists consist of a rugged steel frame, made from structural tubing, which houses a lifting drum and serves as the suspension means for the rated hoist load. An aluminum gearcase, attached to one end of the drum frame, houses a triple-reduction, helical gear train. Applying power to the gearcase is a 2-speed, AC hoisting motor with a 4:1 speed ratio coupled with a 250% torque DC brake. High strength wire rope and a covered lower sheave block act as the load carrying means. Standard equipment includes a rope guide, a rotary-geared limit switch to limit hook travel in both up and down directions and an overload capacity limit switch. An optional block operated limit switch can be used to limit the upward travel of the lower block. An integral trolley, consisting of a 2-speed AC motor and a sealed worm reducer, applies torque to the trolley wheels through a cross-shaft and pinion arrangement, which provides traverse motion to the hoist. A single NEMA 4/12 control enclosure houses both the hoist and trolley electrical system controls. A push button control station (purchased separately) for operating the hoist is suspended on a wire strain cable attached to the hoist. 1-3. SELECTION & APPLICATION GUIDE. Hoist Duty Classification Your SHAW-BOX “World Series” hoist was designed to meet a specific duty classification as described by the FEM “Rules for the Design of Serial Lifting Equipment”. The methodology used to determine the duty class requirements of your specific application is shown below. SHAW-BOX “World Series” hoists are defined as “mechanisms” by the FEM and are classified as such by the following factors: Class of Operating Time and Load Spectrum. Your application must be definable by these two factors in order to determine duty classification. Class of Operating Time Class of Operating Time indicates the average period per day during which the mechanism is in operation, which is anytime the equipment is in motion. The Class of Operating Time is determined by calculation of the average daily operating time (average daily use): Where: t = Average Daily Operating Time (hr/day) H = Average Hoist Height (ft) N = Number of Cycles Per Hour (cycles/hr) T = Daily Working Time (hr/day) V = Hoisting Speed (ft/min) t= 2xHxNxT V x 60 Load Spectrum Load Spectrum indicates the extent of which the mechanism is subjected to maximum stresses (full capacity lifts) or whether it is subject to smaller loads only. Use the charts below to estimate your load spectrum. For an exact means of calculating your load spectrum, refer to FEM 9.511 "Classification of Mechanisms". Once the average daily operating time, "t", is calculated for a specific application, the Class of Operating Time can be identified. Using the Class of Operating Time along with the Load Spectrum, one can determine the duty classification requirement of the application. Defining the proposed equipment usage in this manner is critical to selecting the correct hoist for the application. Classification of Mechanisms Class of Operating Time T2 Load Spectrum L1 L2 L3 L4 ¼- ½ 1Dm 1Cm 1Bm 1Am T3 ½-1 1Cm 1Bm 1Am 2m T4 1-2 1Bm 1Am 2m 3m T5 2-4 1Am 2m 3m 4m T6 4-8 2m 3m 4m 5m Page 3 Average Daily Operating Time (hr/day) Example: An application requires that a hoist be used to repeatedly lift and move small to medium size loads, but occasionally will be required to lift heavy loads equal to 5 metric tonne. This hoist will be operated daily for a single 8-hour shift and will be required to perform 15 lifting cycles per hour. The average height, which the load is lifted, is 18ft at a desired speed of 20ft/min. The average daily operating time can be calculated from the above information: 2-2. INSTALLING HOIST t = 2 x 18 x 15 x 8 20 x 60 = 3.6 hr/day The description of the example application implies that the load spectrum is likely an L1 or L2. Choosing an L2 load spectrum factor and using the calculated average daily operating time, one can determine from the "Classification of Mechanisms" table above, the duty classification for this application is 2m for a 5 metric ton rated hoist. For a more thorough explanation of the determination of mechanism classification, refer to FEM 9.511 "Classification of Mechanisms". Your SHAW-BOX "World Series" hoist was designed to meet the duty classifications as described above. The standard 5t, 10t and 15t capacity models are rated at 2m duty classification, while the 7.5t capacity model is rated at 3m duty classification. Figure 2-1. Trolley Wheel Spacing ("B" & "C" Frame Shown) OPEN-END BEAM: If the trolley can be installed directly from the end of the supporting beam, adjust the spacing between the trolley wheel flanges to be 3/16"-1/4" greater than the exact width of the beam flange (See Figure 2-1). Before adjusting the width of the trolley frame, make sure to loosen the pinion set screws nearest the traverse drive on the keyed cross shaft and those on the traverse reducer. Do not lose the keys for the pinion and reducer during adjustment. Also, the electrical conduit/cable must not be constrained when attempting to adjust the trolley sides, in or out. The trolley width is adjusted by loosening the jam nuts on the traverse drive side of the threaded rods at each end of the hoist. If necessary, lubricate the frame alignment bars with penetrating oil before attempting to adjust trolley width. The trolley side may then be pushed or driven into position by turning the adjusting nuts on the threaded rods. Adjust nuts on each side of the hoist simultaneously, to avoid binding. After adjusting the trolley to the proper width, tighten all adjusting nuts and setscrews, and re-secure the electrical conduit/cable. Verify that the geared wheels mesh properly with the traverse drive pinions. Using proper equipment, carefully lift the hoist and install on the end of the beam. Lubricate the wheel gear and pinion (WG, Section IV, Paragraph 4-5). SECTION II - INSTALLATION 2-1. GENERAL. SHAW-BOX "World Series" electric hoists are lubricated and tested before being shipped from the factory. To place a hoist in service, install onto beam by adjusting appropriately for the flange width, connect to electrical service and perform pre-operation tests and checks. WARNING Only qualified personnel with proper supervision shall install the hoist on the monorail and perform the final pre-operation inspection. NOTICE Loosen all electrical cable or conduit attached to the frame and alignment bars before adjusting trolley width. Ensure that the electrical cable is not stretched, pinched, twisted or otherwise damaged when adjusting trolley width. WARNING Working in or near exposed energized electrical equipment presents the danger of electric shock. TO AVOID INJURY: DISCONNECT POWER AND IMPLEMENT LOCKOUT/ TAGOUT PROCEDURE BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT. CLOSE-END BEAM: For trolleys which are to be mounted along the span of a beam not having open ends, the trolley must be adjusted in the same manner as described above to a width that allows clearance between the axle ends and the beam flange. Using proper lifting equipment, the trolley and hoist must then be lifted to the beam where it is to be installed. Once in position, adjust the spacing between the trolley wheel flanges to be 3/16"-1/4"" greater than the exact width of the beam flange (See Figure 2-1). After tightening all adjusting bolts, set screws, and all electrical conduit/cable clamps, carefully set the trolley on the beam. Lubricate the wheel gear and pinion (WG, Section IV, Paragraph 4-5). Page 4 2-3. CONNECTING HOIST TO ELECTRICAL SERVICE. Electrical service to the hoist may be power cable or a guarded system having sliding shoe or wheel type collectors. Follow ANSI/NFPA 70, state, and local electrical codes including the grounding provisions thereof when providing electrical service to the hoist. Make electrical connections using the appropriate wiring diagrams furnished with the hoist. Only qualified journeyman electricians shall make any electrical connections, including connections to collectors or power cord. WARNING On three phase hoists, it is possible to have "Reverse Phasing" causing the block to lower when the "UP" button is depressed. When this condition exists, the automatic limit switch is inoperative and hoist operation will be dangerous. c) Check Lower Block and Hoisting Cable. Depress "DN" push button and run lower block to its lowest position. No less than two wraps shall remain on the drum with the loaded hook in its lowest position. Also check to see that the lower block and rope do not twist excessively. If it does twist to the extent that two ropes rub against each other, disengage the swaged rope end from the frame anchor and twist the rope four or five turns in a direction opposite to that which the block turns. Reconnect rope to the frame anchor, holding firmly to eliminate rope twisting back to its original position. Operate hoist up and down a few times. If lower block still rotates excessively, repeat process until twisting is corrected. d) Lubricate Hoisting Cable. For longer cable life, it is recommended that the cable be lubricated at time of installation by applying a heavy coating of lubricant CL (Para. 4-7) as outlined in SECTION IV, Paragraph 4-3. e) Check Limit Switch Operation. (1) A geared rotary type upper and lower limit switch is provided as standard equipment on SHAW-BOX "World Series" hoists. This switch is adjustable and although preset by the factory, it should be adjusted at time of installation to the desired high and low limits of lower block travel. Refer to SECTION VII, Paragraph 7-3. (2) A block operated upper limit switch can be furnished as optional equipment on SHAW-BOX "World Series" hoists. This limit stop is factory set to stop the lower block at the safest high position, guarding against over travel and possible damage to hoist. Minimal adjustments can be made. When equipped with this option, the hoist should be tested by jogging the lower block against the limit switch actuator arm to assure the switch is functioning properly. When the lower block lifts the actuator, the hoist will automatically stop. If the lower block coasts through the limit switch when lifting, a reversing switch will automatically close and reverse direction of motion to lowering. f) An overcapacity limit switch is provided as standard equipment on SHAW-BOX "World Series" hoists. This switch is adjustable and although preset by the factory, it should be adjusted at the time of installation to the desired setting. Refer to SECTION VII, Paragraph 7-4. g) When first using the hoist and trolley, operate with lighter loads through full travel before applying maximum load. WARNING Be certain that electrical power supply is OFF and locked in the open position before attempting any electrical connections to the hoist. This equipment must be effectively grounded according to the National Electric Code ANSI/NFPA 70, or other applicable codes. CAUTION Power supply to hoist and trolley must be the same voltage, frequency, and phase that are specified on the hoist and trolley nameplate. 2-4. PRE-OPERATIONAL CHECKS a) Check Oil Level. (Figure 2-1) The gearcase has been filled with oil to the proper level. However, this should be rechecked before operating the hoist. Check oil level by removing the plug indicated in Figure 2-1. When properly filled, oil should be level with the bottom of the tapped hole. Fill to this level with oil as specified in Paragraph 4-2.e. b) Check Push Button Operation and Phasing. To properly check the phase of the hoist, follow these steps: (1) With "POWER OFF", operate all the push buttons and determine that they do not bind or stick in any position. WARNING If any push button binds or sticks in any position - DO NOT TURN POWER ON - determine the cause and correct the malfunction before operating. (2) Connect hoist to power source. (3) Operate "UP" button briefly to determine direction of hook travel. (4) If hook raises when "UP" button is depressed, phasing is correct. (5) If hook lowers when "UP" button is depressed, hoist is "Reverse Phased." TURN AND LOCK POWER OFF and check the pushbutton wiring. If the pushbutton was wired properly, correct the problem by interchanging any two leads at power source connection. Do not change internal wiring of hoist. Page 5 break in by operating under lighter loads to full travel before applying maximum load. b) DO be familiar with hoist operating controls.) For the hoist motion depress push button marked "DN" to lower load. a) DO read applicable sections of FEM Section IX. q) DO use hook latches. c) DO make sure hook travel is in the same direction as shown on the controls. and warnings. b. Safe operation of an overhead hoist is the operator's responsibility. u) DO NOT use damaged hoist or hoist that is not working properly. see Pre-Operation Checks. ">>" or "N". the hoist can be controlled to give fast lifting and lowering. Series Lifting Equipment and the Operation. procedures. l) DO warn personnel of an approaching load. resulting in damage to equipment or injury. k) DO make sure that all persons stay clear of the suspended load. With it. may save injury to personnel and damage to equipment.OPERATION 3-1. t) DO NOT use the hoist load-limiting device to measure the load. e) DO maintain firm footing when operating hoist. Section II. replace damaged or worn parts. "S" to activate the trolley traverse motion. w) DO NOT lift a load unless wire rope is properly seated in its groove(s). n) DO promptly report any malfunction. Service and Parts Manual. TO AVOID INJURY: UNDER NORMAL OPERATING CONDITIONS. Failure to do so may allow hoist to be operated beyond proper travel limits. "S" to activate the trolley traverse motion With one speed control depress buttons marked "<" . m) DO protect wire rope from weld splatter or other damaging contaminants. in addition to frequent examinations and periodic inspection of the equipment. v) DO NOT use the hoist with twisted. WARNING Some hoists may be shipped with the electrical controls loose (disconnected) and will not have the upper and lower limit switches connected. SECTION III . ">" or "N". If opposite direction occurs. d) DO make sure hoist limit switches function properly. o) DO inspect hoist regularly. and injury may result if limit switches fail due to improper use. Page 6 . d. Paragraph 2-4. Operation of SHAW-BOX "World Series" hoists is controlled by a convenient pendant push button station. lift a few inches and check load's holding action before continuing. f) DO make sure that the load slings or other approved attachments are properly sized and seated in the hook saddle. The push button station has a built-in interlock to prevent depressing opposing buttons simultaneously. 3-3. or worn wire rope.WARNING Damage to the hoist. s) DO NOT lift more than rated load. When first using the hoist. h) DO make sure that load is free to move and will clear all obstructions. DO NOT OPERATE HOIST UNTIL LIMIT SWITCHES ARE PROPERLY CONNECTED AND ADJUSTED. or controlled to lift or lower the load in small increments. unusual performance. 3-2.) On two-speed hoist or trolley motions. providing accurate positioning capability. x) DO NOT use wire rope as a sling or wrap rope around the load. kinked. check load balance.) For the trolley traverse motion: With two speed control depress buttons marked "<<" . CAUTION Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons. Listed below are some basic rules that can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others. c. a dropped load. r) DO apply lubricant to the wire rope as recommended. STOP HOIST TRAVEL BEFORE ENGAGING LIMIT SWITCHES. damaged. partial depression of a button operates hoist or trolley at slow speed. depressing button completely operates hoist or trolley at full speed. CAUTION Excessive "jogging" will cause premature burning of contact tips. i) DO take up slack carefully. Observance of these rules.b. GENERAL.) For the hoist motion depress push button marked "UP" to raise load. OPERATING PRECAUTIONS. g) DO make sure that the hook latch is closed and not supporting the load. motor overheating and premature brake wear. or damage of the hoist. j) DO avoid swinging of load or load hook. p) DO use the hoist manufacturer's recommended parts when repairing a hoist. PUSH BUTTON OPERATION a. which can cause load to drop. LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULD NOT BE USED AS NORMAL OPERATING CONTROL. and keep appropriate records of maintenance. support. This may result in dropping the load that can cause damage to equipment and injury to operator or other personnel.b. excessive side pulls. however. The lubrication services outlined in Paragraphs 4-3 thru 4-6 should be performed before initial operation of the hoist. 4-2. coinciding with spring and fall seasons is recommended. cc) DO NOT operate the hoist beyond limits of wire rope travel. uu) DO provide supporting structure that has an appropriate design factor based on the load rating and dead weight of the hoist. kk) DO NOT remove or obscure the warnings on the hoist. ii) DO NOT allow the rope or hook to be used as a ground for welding. b) Remove oil drain plug from bottom of gearcase and drain oil out. ll) DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance. pp) DO NOT operate hoist unless limit switches are operating properly. Avoid side pulls and swinging of load or load hook when traveling hoist. when starting to lift. CHANGING GEARCASE OIL Figure 4-1. The lubrication services outlined in Paragraphs 4-2 thru 4-6 should be performed at regular intervals at least every six (6) months. If opposite direction occurs.f. hh) DO NOT allow sharp contact between two hoists or between hoist and obstructions. See Section V. nn) DO NOT allow personnel not physically fit or properly qualified. see pre-operation checks. to operate hoist. may cause damage to the rope guide causing the rope to leave the grooves. cleanse the area with a waterless hand cleaner and follow by washing thoroughly with soap and water. or transport people. ee) DO NOT use hoist to lift. The operation shall be continued only after the operator is assured that the hoist is operating properly and that the load is supported in the center of the base bowl/saddle of the hook. The reason for this is that on hoists installed outside or in unheated areas a "cold test" oil is required in such (below freezing) climates making seasonal changes necessary. This will clean components and hold particles in suspension for draining. gg) DO NOT leave a suspended load unattended unless specific precautions have been taken. WARNING Avoid skin contact with Mobilsol A. SECTION IV . jj) DO NOT allow the rope or hook to be touched by a live welding electrode. mm) DO NOT attempt to lengthen the wire rope or repair damaged wire rope. z) DO NOT apply the load to the tip of the hook. consult a structural engineer. Such operation may result in damage to the rope guide and rope and could result in the rope breaking. bb) DO NOT allow your attention to be diverted from operating the hoist. y) DO NOT lift a load if any binding prevents equal loading on all supporting ropes. rr) DO operate hoist within recommended duty cycle and DO NOT "jog" unnecessarily. aa) DO NOT operate unless load is centered under hoist. GENERAL. qq) DO avoid operating hoist when hook is not centered under hoist. They are emergency devices only. oo) DO NOT operate hoists unless hook moves in the same direction as indicated on the push button. ww) D O. tt) DO NOT operate hoist with hooks that have opened up. slack or kinked rope.LUBRICATION 4-1. If in doubt of the supporting structure's strength. Paragraph 5-2. yy) DO use common sense and best judgment whenever operating a hoist. Page 7 . ss) DO conduct regular visual inspections for signs of damage and wear. View of Hoist Showing Location of Name Plates and Oil Plugs ("B" & "C" Frame Shown) a) Add 5% solution of Mobilsol A (or equivalent) to the oil and run for a short time. Dispose of oil in accordance with local environmental codes. In case of skin contact: dry wipe the skin. WARNING DO NOT operate hoist with the hoisting rope out of the drum grooves. move the load a few inches at which time the hoist should be checked for proper load holding action. xx) DO observe recommended inspection and maintenance procedures. swinging or jerking of load. ff) DO NOT lift loads over people. Hoist rope will remain in the drum grooves during operation under normal operating conditions. Section II Paragraph 2-4. dd) DO NOT use limit switches as routine operating stops unless recommended. or similar abuse. vv) DO NOT use hoist in location that will not allow operator movement to be free of the load. It is lubricated prior to installation at the factory and requires only periodic inspection. the rope guide should be thoroughly greased with MPG (Paragraph 4-7) and the hoist run up and down to lubricate both the drum and the wire rope. The amount of oil required depends on the overall size of the gearcase. To determine size and amount of oil to add. It is recommended that the cable be thoroughly coated at installation and kept well lubricated with CL (Paragraph 4-7). Gearcase Width Illustration e) Refill through filler hole to proper level (bottom of oil level plug hole) using GCOH (Paragraph 4-7). measure the width of hoist gearcase (see Figure 4-2). Hoists are shipped from the factory without an exterior coating of grease on hoisting cable. the rope guide should be removed per Section V. 4-4. cleaned and inspected. LUBRICATION OF HOISTING CABLE. Provide a light film of grease MPG (Paragraph 4-7) on bevel gear of rotary geared limit switch. d) Remove oil level plug from front of gearcase cover. (1) Periodically re-grease with MPG (Paragraph 4-7) by applying grease to the leading edge of the guide and rope drum. Figure 4-2. LUBRICATION OF LIMIT SWITCH. c) Reinstall drain plug. The rope guide is made of a molded self- lubricated reinforced nylon material. The "C" Frame measures 12-1/2" and requires approximately 11 quarts of oil. Notes Page 8 . When reassembled. three sizes are used for "World Series" hoists. The "B" Frame measures 9-3/4" wide and requires approximately 5 quarts of oil. LUBRICATION OF ROPE GUIDE a) Maintenance. At installation and periodically. 4-3. Paragraph 5-5. (2) Every 6 months. apply grease WG (Paragraph 4-7) to the traverse drive pinions and the gears of the trolley wheels. 4-5. 4-6. LUBRICATION OF GEARED TROLLEY WHEELS AND PINIONS. The "D" Frame measures 17" and requires approximately 12 quarts of oil. Texaco ® Inc. Texaco ® Inc. Texaco ® Inc.235 SUS 284 . WG Wheel Gear and Pinion Grease CL Cable Lubricant Wire Rope Lubricant GO General Oil General Oiling to Prevent Rusting and Provide Limited Lubrication for Points Not Considered Normal Wear Points Viscosity @ 100° F Mobil ® Oil Corp. 6 1335 .295 360°F (182°C) Lithium Amolith ® Grease No. 1 193 . No Specification Amoco ® Oil Co. LUBRICANT SPECIFICATIONS -20° to +50° F (-29° to +10°C) GCOH Gear Case Oil Hoist Gearcase AGMA Lubricant Viscosity @ 100° F Viscosity Index Pour Point Mobil ® Oil Corp. 1 154 -40°F Mobil ® SHC 632 Omala ® RL 320 Pinnacle ® 320 No. MPG Multipurpose Grease NLGI Grease 6ASTM Worked Penetration 310 . Mobil ® Oil Corp. Shell ® Oil Co. -20°F (-29°C) Rykon ® Oil 46 Rotella ® 10W Sunvis ® 932 Rando ® Oil 46 No. Sun ® Oil Co.347 SUS 60 Min. 7 1919 . Couplings Shell ® Oil Co. Sun ® Oil Co. Shell ® Oil Co. Texaco ® Inc.000 SUS (contains diluent) ---------------------------------------.Mobiltac ® 375 NC ---------------------------------------------------------------------.1632 SUS AMBIENT TEMPERATURE 50° to 125° F (10° to 52°C) No. SG Spline Grease NLGI Grease ASTM D217 Worked Penetration Dropping Point Base Mobil ® Oil Corp.Retinax LC ------------------------------- Refer to SHAW-BOX Hoist Field Service Department for Gearcase Operating Temperatures above 125° F .7. Mobil ® Oil Corp. Sun ® Oil Co.Crater H ® ------------------------------------------------------------------------. 2 ------------------------------------.2346 SUS 158 -37°F Mobil ® SHC 634 Omala ® RL 460 Pinnacle ® 460 Texclad ® 2 No. 8 or 8C (Compounded) 680 Cylinder Oil #680 Mobil ® SHC 634 Synthetic.Mobil ® 600W Valvata ® J460 Meropa ® 460 60 Min. 7 or 7C (Compounded) 460 Worm Gear Oil Mobil ® SHC 634 Synthetic.Sunoco ® Wire Rope Lubricant --------------------Crater A No. Mobil ® Oil Corp.Mobilarma ® 798 ----------------------------------------------------------. Texaco ® Inc. or Gear Type Flexible Mobil Oil ® Corp.2346 SUS 95 20°F Mobilgear ® 634 Omala ® 460 Meropa ® 460 No.Amovis ® 5-X --------------------------------------------------------------------. 2 265 . GCOT Gear Case Oil Traverse Gear Case AGMA Lubricant ISO Viscosity Grade Amoco ® Oil Corp. 2 EP Mobilith ® AW 2 Sunoco ® Multipurpose 2 EP Multifak ® EP 2 No.Mobil ® DTE Oil Heavy -------------------------- Dropping Point Grease Lubricated Base Wear Points Provided with Fittings and Grid Amoco Oil ® Co. Texaco ® Inc. Shell ® Oil Co.Mobilux ® EP 111 ---------------------------25. AGMA Lubricant Viscosity @ 100° F Viscosity Index Pour Point Amoco ® Oil Co.4. 1 310 . --------------------------------------------. 7 EP 1919 .340 320°F (160°C) Lithium ---------------------------------------.Extra Hecla Super Valvata ® J680 Meropa ® 680 Page 9 125° to 250° F (52° to 121°C) No. 10°F (-12°C) American Industrial Oil ® 68 Rotella ® 10W-30 Sunvis ® 968 Rando ® Oil 68 No.340 360°F (182°C) Lithium Amolith ® Grease 1 EP Mobilith ® AW 1 Prestige ® 741 EP Multifak ® EP 1 No. Many factors influence the inspection and preventative maintenance program required for your hoist. and ordering of replacement parts. In addition. appointed maintenance personnel inspecting hoist can also take care of minor adjustments. and environment of your hoist. Regular in-service inspection and preventative maintenance programs not only help reduce overall maintenance costs but may also prevent service shutdowns by forewarning of problems that could cause these shutdowns. Series Lifting Equipment or the Hoist Duty Classification page in this manual. or whoever reviews the inspection reports. Periodic review of old inspection reports can point out service life of hoist components. Written. service. that deficiencies exist. add additional units or provide a similar form to suit particular conditions that may exist. The Pulse monitor takes the "pulse" of the equipment by recording the most recent hoist activities including all normal operation events. which will retain data even when the hoist is removed from power. runway components. repair or replacement of these components. The inspection and maintenance intervals outlined in this section are considered a minimum. Attention must be given to applicable federal standards. Inspection Schedule and Maintenance Report Form.INSPECTION AND PREVENTIVE MAINTENANCE 5-1. regular cleaning and lubrication and replacement of worn parts can help preserve good performance and operation of your hoist. repairs and cleaning. such as corrosive vapors. Your SHAW-BOX "World Series" hoist was designed to meet a specific duty classification as described by the FEM "Rules for the Design of Serial Lifting Equipment" and is to be used in accordance with the duty rating identified on the equipment nameplate. when adjusting hoist inspection and maintenance programs to local conditions. local environmental conditions and various applicable codes are some of the factors that the user must consider to adjust inspection and maintenance program outlined in this section to meet his specific conditions. The form also includes trolley components. In this manner. File and review these reports after each inspection. All SHAW-BOX "World Series" hoists are inspected and tested at the factory. This form does not supersede the Inspection and Maintenance Schedule listed on page 11 of this manual but may be used to record scheduled inspection and maintenance services required. drums and brakes. It is strongly recommended that the Inspection Schedule and Maintenance Report. be completed by a qualified person designated with the responsibility for hoist operation and safety or an inspector appointed by this person. Inspections are recommended each month and should be performed thoroughly enough to inform the hoist user of Page 10 deficiencies for any item listed. Regular inspections. OSHA regulations. please reference FEM Section IX. Listed on the Recommended Inspection and Maintenance Schedule are inspection frequencies and requirements. shown herein. Frequency and severity of service and material handled. state and local codes which may include mandatory rules relating to hoist inspection and maintenance. and miscellaneous items. which is wired into the control circuit in the control enclosure. extreme heat or cold. For more details regarding hoist duty cycles and average daily use. Perform these inspections regularly as scheduled and additional inspections as may be required for activity. Do not operate a hoist having deficiencies unless a designated qualified person has determined that these deficiencies DO NOT constitute a safety hazard. items requiring further attention will be checked (√) without showing corrective action. The user should carefully consider all environmental conditions and adjust frequency and degree of maintenance for his local conditions. The user should become familiar with all applicable codes for his area and be guided accordingly. The user should revise the inspection interval. where required. WARNING Deficiencies may be hazardous to personnel and equipment. repairs. dated and signed inspection reports for many items are mandatory under OSHA regulations. national standards. hoisting rope. forecasting need for adjustment. Note column on Inspection Schedule and Maintenance Report form headed Corrective Action and Notes. cement or dust and other airborne contaminants. Various codes also regulate inspection and maintenance programs. note condition of part or unit as inspected in appropriate Condition column with a check mark (√). GENERAL. dated and signed inspection reports should be maintained particularly on critical items such as hoist hooks. Consult the factory's Field Service Department for advice regarding unusual environmental conditions. Frequency of inspection and maintenance must be increased if hoist is subjected to severe atmospheric environmental conditions. The designated person will check all deficiencies as listed and re-examine or otherwise determine whether they constitute a safety hazard. . This form is suggested as a guide for written inspection reports. Inspection records can point out the service life of hoist components and help forecast the need for adjustments. This will advise the person responsible for hoist operation and safety. over-capacity lifts and thermal overload events. The hoist operator must be responsible for determining the operating conditions and severity of service. As a matter of expedience. sheaves.SECTION V . and many state safety codes. Shown on page 12 of this manual is a recommended Inspection Schedule and Maintenance Report form that lists various components of the hoist. periodic minor adjustments. Recommended in the schedule are minimum inspection and maintenance intervals based on average daily use in a normal environment. However. Note "during inspection" corrective action taken and date in space provided. All SHAW-BOX "World Series" hoists are equipped with a Pulse™ monitor. and onboard memory. written. motor starts. When corrective action is made during inspection. Environmental conditions in which the hoist operates are also important considerations for the user. a serial communications port. Each Pulse monitor is programmed with the equipment serial number at the factory. the monitor records the total cumulative operating time and motor starts for the life of the equipment. This equipment consists of a circuit board. Lubricate outboard bearing cartridge at grease fitting. Lubricate hoist cable per Paragraph 4-3. Lubricate upper and lower hook block. Inspect hooks with crack detecting procedures per Paragraph 5-2.e. Notes Page 11 . RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE TIME INTERVAL Daily or start of each shift (visual) 1 Month 1-3 Months INSPECTION OR MAINTENANCE * Check operation of all functional mechanisms including limit switch operation. Hours of "on" time Load Spectrum L1 L2 L3 L4 Hoist Duty 2m 12500 6300 3200 1600 3m 25000 12500 6300 3200 * Complete inspection. abrasions. * HOIST CABLE . The data can also be helpful in establishing and scheduling preventative maintenance as well as an aid in troubleshooting the equipment. 6 Months Annually * Complete inspection. OVER-CAPACITY LIMIT SWITCH-Inspect per Paragraph 5-13. upper and lower blocks. Add a light film of MPG grease to the bevel gear in the screw type limit switch per Paragraph 4-7. Inspect hooks. corrosion or broken wires or evidence of improper spooling on drum. Pulse monitor data may be used to determine equipment usage and to verify that the application does not exceed the hoist duty rating as identified on the equipment nameplate.Inspect per Paragraph 5-4.Inspect per Paragraph 5-6 and lubricate per Paragraph 4-3. via the serial communications link. * ELECTRICAL CONTROLS .Data may be downloaded from the monitor. and all load bearing components for damage. Motor brake and actuating mechanisms inspected and adjusted per Paragraph 5-10. ROPE GUIDE-Inspect per Paragraph 5-5. by a certified technician. It is recommended that your SHAW-BOX repair Station be contacted for this service. UPPER BLOCK -Inspect per Paragraph 5-3. * * * * * * LOWER BLOCK -Inspect per Paragraph 5-2. BLOCK OPERATED LIMIT SWITCH (if equipped)-Inspect per Paragraph 5-12. brakes and control. For additional information refer to the Pulse monitor manual (P/N 11817503) sent with this manual. disassembly and maintenance required.add oil as required per Paragraph 4-2. Check hoist cable for kinks. Check hoist gearcase oil level . Grounding Faults * See text for DAILY & WEEKLY REQUIREMENTS.) DATE LOCATION Motor Motor Brake Mechanical Load Brake Overload Clutch Couplings Gears. Rust or Corrosion) SEMI-ANNUAL CLEANING OR PAINTING REQUIRED ADJUSTMENT REQUIRED MONTHLY ANNUAL CORRECTIVE ACTION NOTES COMPONENT. UNIT OR PART (Indicate corrective action taken during inspection and note date. RUNWAYS Rope Slings & Connections Change Gearcase Lub.) REPLACEMENT REQUIRED (Worn or Damaged) REPAIR REQUIRED (Loose Parts or Wires) LUBRICATION REQUIRED (Low Oil or Grease. INSPECTION INTERVAL. X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED. Page 12 GOOD 12375gwr . When corrective action is completed. Use note column to Interval the right if condition is not listed below. a designated person must determine that the existing deficiency does not constitute a safety hazard before allowing unit to operate. describe and note date in this column. For corrective action to be done after inspection. UNIT OR PART and location * Recom- CONDITION mended (Check column best indicating condition when Inspection part or unit is inspected. SIGNED & DATED REPORT REQUIRED – OSHA.__________________________ RATED LOAD_____________________ LOCATION IN PLANT_______________________________________ TYPE_ ____________________________ THIS INSPECTION IS MONTHLY ANNUAL VOLTAGE_________________________ SEMI-ANNUAL INSPECTED BY:____________________ DATE________________ COMPONENT.INSPECTION SCHEDULE AND MAINTENANCE REPORT HOIST SERIAL NO. Shafts & Bearings HOIST Upper Block Lower Block Hook & Throat Opening Hoist Rope Rope Drum Rope Guide Guards Limit Switches X Record Hook Throat Opening CONTROL STATION OR PUSH BUTTON Pushbutton Wiring Motor Brake (when so equipped) Couplings Gears. Shafts & Bearings TROLLEY Frame Wheels Bumpers Guards Conductors Collectors RESISTORS Hoist Trolley Monorail Joints Monorail Main Conductors Main Collectors General Condition Load Attachment Chains MISC. Typical Inspection Schedule and Maintenance Report form. (MFGRS)___________________________ CUSTOMER CRANE IDENTITY NO. User must adjust inspection interval and components to suit his individual conditions and usage. INSPECTION OF ROPE GUIDE a) General. Bearings without grease fittings are lubricated for the life of the bearing and require no further lubrication. Failure of these components may result in injury. a measurement be made and recorded of the hook throat opening. d) Make certain that the spring pin holding the hook nut to the hook is securely in position. Figure 9-4. magnetic particle. limit stop switches and the hoist contactors. Paragraph 4-7). then determine component location and identity on your hoist. Danger may be present that the hoist operator cannot see. Gage Block g) Hooks showing signs of cracks must be replaced. b) Check each sheave to insure rope groove is smooth and free from burrs. WARNING Figure 5-2. c) Check each sheave for freedom of rotation. Trolley contactors and optional hoist and trolley fuses are also located in this enclosure. Replace worn or damaged bearings. INSPECTION OF ELECTRICAL CONTROLS Arrangement of electrical control equipment varies with the type of control. b) Check condition of contactor assembly. check to determine that they are in good operating condition. f) Check throat opening of the hook. a) Check upper block sheaves for wear. INSPECTION OF LOWER BLOCK Refer to the Section IX. Determine and correct the cause of unusual conditions and make certain hoist can be operated safely. Figure 9-5. a) Open hinged control panel enclosure cover mounted to the counterweight and inspect wiring and terminals. 5-3. physical space and the optional control features ordered with the hoist. sounds. OSHA regulations require that the hook be replaced if the throat opening exceeds 15 percent of the original opening. or if the hook is twisted more than 10 degrees from the unbent plane. pins. We suggest that a gage block properly identified to the hoist. 5-5. Side pulling and excessive load swing will severely damage the rope guide and must be avoided. and upper limit switches. or other surface defects. transformer. . replace bearings if defective. 5-4. WARNING Be certain that main power switch is locked in open position (OFF) before opening hinged control enclosure cover mounted to the counterweight. transformer. damage and freedom of rotation. e) If hook is equipped with a hook latch or rotational lock. disassemble block and inspect bearings. similar to the one shown in Figure 5-2. Terminals should be securely crimped to wires and insulation sound. The rope guide is intended to help prevent the rope from "back-winding" and to hold the rope in the proper groove. washers. be made for each hook for use in these measurements. Use wiring diagrams furnished with hoist to determine electrical components on your hoist. c) Make certain that the rope retention bolts are not bent. b) Make certain that all sheaves. loose or otherwise distorted. (Refer to Figure 5-2. h) Check wear of the hook. bearing and hanger pins are free of foreign material. especially at the saddle and replace if worn more than 10% of original dimensions. Also lubricate the shank of the hook that passes through the crosshead. If the thrust bearing is removed. INSPECTION OF UPPER BLOCK Refer to the Section IX. a) Check lubrication of all parts. bolts must have close clearance to sheave flange to keep rope in sheave grooves. 5-2. If sheaves do not rotate freely. or other suitable non destructive test methods. Page 13 Side pulling and excessive load swing will severely damage the rope and rope guide.WARNING Do not operate a hoist having unusual vibrations. apply MPG grease (Section IV. Lower Block Assembly. Terminal screws should be tight.) It is recommended that upon receipt of the hoist. or sheaves. or with anything visibly or otherwise wrong. Note the location in the electrical enclosure of the control circuit fuse. Hooks should be inspected at least once per year using dye penetrants. Upper Block Assembly. refer to the parts list in Section IX. (4) Follow steps in reverse to re-install. The two halves of the rope guide body (Item 1) can now be pulled off the drum separately. refer to the parts list in Section IX. (3) Thoroughly clean and inspect all components. (3) Carefully unhook the rope tensioning spring (Item 5). (1) Remove socket head cap screws and lock washers (Items 6 and 7). (5) Thoroughly clean and inspect all components. When reassembling the rope guide. the halves will separate and. Refer to Fig. Rope Guide Assembly ("D" Frame) 5-6. Be sure to regrease the rope guide with MPG (Paragraph 4-7). (1) Remove hex head cap screws and lock washers (Items 1 and 2). Be sure to regrease the rope guide with MPG (Paragraph 4-7). 5-3a. ROPE INSPECTION. which is under tension. Refer to Fig. use caution when unhooking to avoid injury. if not properly supported. Figure 5-3a. c) D isassembly for "D" Frame. Note the required orientation of the rope guide assembly for re-installation. paying attention to orientation and making sure to seat the assembly into the correct drum groove. Page 14 . WARNING Once shoulder bolts are removed. (2) Remove shoulder bolts (Item 3) and compression springs (Item 4). MAINTENANCE AND REPLACEMENT WARNING Wire Rope improperly handled or abused can create a SAFETY HAZARD. WARNING The rope tensioning spring is under considerable tension. Read and comply with inspection. (2) Slide the rope guide assembly (Item 4) off the end of the drum frame rod and remove from drum groove area. 5-3b. Rope Guide Assembly ("B" & "C" Frame) b) Disassembly for "B" & "C" Frame. Remove drum frame rod (Item 8). maintenance and replacement information given herein. after assembling. For further assistance in locating components. (4) Remove the split plastic shroud (Item 2) from the drum. after assembling. be sure the plastic shroud (Item 2) fits snugly in the rope guide body groove. the halves could fall. For further assistance in locating components. When reassembling be sure that the half with the rope slot is on the top half of the drum. (6) Follow steps in reverse to reassemble. Pull back on drum frame rod assembly (Item 3) until the free end pulls free of the gearcase end drum bracket. Figure 5-3b. Special attention is required to lubricate sections of rope over equalizing sheaves and other hidden areas. the rope should be replaced. namely Section 9. (3) Replace wire rope. To assist the reeving diagram describes the reeving old rope. b) Maintenance. Wire rope should be thoroughly inspected at regular monthly intervals by an authorized person and a determination made when further use of the rope would constitute a safety hazard. When first using hoist after rope replacement. Replacement rope assemblies are shipped from the factory carefully coiled to prevent damage by kinking.4 Part Single Reeved. of the regular maintenance program. Installation. if rope has suffered heat damage from any cause. kinks. or induce sharp bends in the rope. Figure 5-4. permanent bends.661. break in rope by operating under lighter loads to full travel before applying maximum load. Wire rope on your hoist is one of the most important components requiring frequent inspection and maintenance. (2) Replace wire rope. Keep rope well lubricated to help reduce internal friction and prevent corrosion. If coil or reel does not rotate the wire will be twisted as it is uncoiled and kinking will result. bird-caging or especially heavy wear. with re-reeving your hoist. b) Before removing the Figure 5-5. 12169 CAUTION It is imperative that rope reel or coil rotates as rope unwinds. Care must be taken to avoid twisting or kinking when uncoiling and handling during reeving. All wire ropes will eventually deteriorate to a point where they are not safe and will require replacement.Care. but not limited to the following conditions. which may be identifiable through visual inspection of rope color. Please refer to FEM Section IX. if rope exhibits swelling. Reeving Diagram . c) Replacement. (4) Replace wire rope. crush. should be applied as a part UPPER BLOCK DRUM LOWER BLOCK Figure 5-5. "Dimensions and Design of Rope Reeving Components" and ISO 4309. Avoid dragging ropes in dirt or around sharp objects that will scrape. as described in Paragraph 4-3. 5-7. Ropes will wear more quickly in areas that are more frequently in contact with the running sheaves and drum. Inspections should take place at the most active sections of the rope. nick. (7) Rope being idle for one month or more due to shutdown or inactivity. crushing. Before replacing rope. Each inspection should include a written dated and signed report of rope condition. WARNING Use only factory-approved rope with swaged wire rope socket. refer to and corresponding paragraph that procedure. ROPE REEVING a) General. if a complete strand has broken. bruises.) Page 15 . Examination and Discard". Inspections revealing. Correct Method of Measuring Rope (5) Rope corrosion and/or rust formation. internal or external. Maintenance. Series Lifting Equipment. Special attention should be exercised when inspecting rope normally hidden during inspecting procedures. (Note: Arrow on Drum Indicates Direction of Drum when Lowering. Place reel on stand with shaft through the center of reel so rope can be pulled straight out with reel rotating. "Wire Ropes . When recommended by an authorized inspector. a) Inspection. (6) Effects from improper lubrication. Reports should be filed and reviewed each month and any rope deterioration carefully noted. check condition of grooves in sheaves and drums to determine if they are excessively worn. A kinked rope may be damaged and unsafe for maximum service. refer to reeving diagram. (1) Replace wire rope if the number of visible broken wires exceeds 13 over a length of 6 times the nominal diameter (6d) or exceeds 26 wires over a length of 30d. Lubricant. should cause inspector to question remaining strength of rope and consider replacement. for illustrations and definitions when following the above guidelines for rope inspection. Page 16 .) (b) With the rope lying in the bottom of the drum groove. (c) Applying tension to the rope and keeping it properly seated in the drum groove. (Lower block may be lowered to the floor if desired. (1) Thread rope to drum from trolley frame side then secure with rope clamps as follows: (a) Make sure that the rope clamp groove size. (7) Securely grasp the upper block sheave before carefully sliding the sheave pin out. Check limit switch operation carefully. (5) With outer lower block covers removed. NOTE It may be necessary to adjust the geared limit switch in order to completely unwind all of the rope from the rope drum. Please refer to Section IX to assist in locating components referred to in the following paragraphs. (8) Lubricate cable per Paragraph 4-3.TURN ON POWER. Securely grasp the swaged wire rope before removing the pin. d) Installing new rope. WARNING Winding rope on rope drums with power can be hazardous. (6) Remove one retaining ring on upper block to allow removal of upper block sheave pin. and outlined in Section V. (3) Operate hoist "UP" guiding six (6) wraps of new rope into drum grooves with gloved hand. without load. thread the wire rope through the sheaves of the upper and lower block as shown in Figure 5-5. before placing hoist in service. (4) Reinstall rope guide over rope in rope drum grooves as shown in Figure 5-3a. Continue lubricating as rope is spooled onto the drum until about 28'-0" remain unwound. (1) To remove rope twist in four part single reeved hoists: (a) Observe direction block tends to rotate. (5) Remove two (2) rope retention bolts and nuts from upper block yoke. & 5-3b. adequate scaffold below the hoist is recommended. Stop hoist so all (3) rope clamps are accessible. (2) Remove the cap screws and hex nuts that retain the lower block sheave covers. Keep hands safe distance from drum. (4) Slide out lower block sheaves and remove wire rope. (d) TURN ON POWER. matches the rope size for your hoist (9mm on the "B" Frame. to handle less weight and for ease of reeving. Remove rope clamps and wire rope from drum. install the remaining two clamps to the specified torque above. (10) Remove rope guide per Section V. (7) Replace the lower block sheave covers. begin by tightening the rope clamp at the tail end of the rope. however. (88-95 N-m). Paragraph 5-5. raise and lower the block several times to feed the correcting twist in the rope through the reeving. Allow 3" for hook drift in both directions. (8) Remove wire rope from sheave. Do not allow less than two (2) complete wraps of rope on drum with hook in lowest position. (34-40 N-m). (6) Attach swaged rope end to the dead end anchor pin and fasten with either the new cotter pin provided with the rope ("B" & "C" Frame) or the retaining rings provided with the hoist ("D" Frame). Note that two spacers will also be released as the pin is removed. wear gloves and use extreme care when winding rope. Remove covers. (11) Make certain all personnel are clear of hoist and operate hoist "DN" to completely unwind all wire rope from drum. WARNING Geared limit switch must be reset after replacing wire rope. as marked on top of the clamp above the groove. (9) Remove cotter pin from dead end anchor pin. 12mm on the "C" Frame and 15mm on the "D" Frame). CAUTION Be certain all personnel are clear of hoist as components. Torque the "D" Frame clamp to 65-70 ft-lbs. c) Removing old rope. (2) With all personnel clear of hoist . (b) Lower the block to a low position and TURN OFF (lock out) POWER. Paragraph 5-5. WARNING The hoist must be removed from service and placed on the ground for any maintenance that requires removal of the output shaft assembly or drum. Torque the "B" and "C" Frame clamp to 25-30 ft-lbs. (3) Remove retaining rings from lower block sheave pin. e) Checking for and removal of rope twisting. SEVERE DAMAGE AND/OR A DROPPED LOAD COULD RESULT. hardware. (1) Lower the lower block to a scaffold 6 to 7 feet below hoist to relieve tension on wire rope. and wire rope are removed from hoist. (c) Remove swaged fitting from anchor pin and rotate rope several turns in a direction tending to correct block rotation. Figure 5-6. and resting lower block on work surface so all weight is off rope drum. These bolts are not to be removed. (2) Make sure power to hoist is off and locked out. as outlined in Section V. g) Inspect the gearcase output shaft and drum splines for wear. prevent rope drum from free spinning by wedging drum in place with a block of wood. On the "D" Frame hoist. b) Remove the geared limit switch or disconnect the wires so that the electrical cable will not inhibit removal of the drum. lightly tap on the top and bottom cover tabs to release.) (1) Lower hook block to the floor and relieve all load from ropes. (See Figure 5-7. Page 17 Figure 5-7. (3) Drain the oil from the gear case per Section IV. by reversing above instructions. Rope may also be removed from hoist drum. Drum Frame & Geared Limit Switch ("B" & "C" Frame Shown) 5-8. place it on the ground and provide adequate means to support the drum before removing the frame rod cap screw(s) and stiffener plate hardware ("B" & "C" Frame only) at the outboard end drum frame (see Figure 5-6). the oil must be drained from the gear case. h) Before re-assembling. One end of the rope drum is supported on this output shaft. Since the entire motor shaft is submerged in oil. Hoist Gear Case Assembly ("B" & "C" Frame Shown) . (440 N-m). Remove the smaller socket head cap screws and lockwashers holding the cover to the gearcase. WARNING Before disassembly. The hoist gear case is a triple-reduction. The gear shafts are supported with ball and roller bearings housed in the back of the case and in the cover. it will disengage from the drum allowing the drum to drop. with exception of the integral output shaft. On the "B" and "C" Frame hoists. check to make sure that the two (2) hex bolts securing the gearcase to the drum frame bracket are in place and tightened securely. respectively. Paragraphs 5-5 and 5-7. INSPECTION OF ROPE DRUM AND SHAFT a) To remove the rope drum. Torque "B" Frame drum mounting bolts to 170 ft-lbs. b) Inspection and Disassembly.. The output shaft passes through an oil seal in the back of the gear case and drives the drum by means of a crowned spline. f) Keeping the drum level. (4) On the "B" and "C" Frame hoists. (5) Provide adequate means to support the gearcase cover. remove the four (4) socket head cap screws that protrude through the cover and gearcase. Carefully draw the cover directly away from the gearcase. Be certain all shaft assemblies stay in the case. remove the drum from the splined output shaft at the gear case end. the bolts supporting the gearcase are installed through tabs on the outside of the housing and do not pass through the cover. remove the rope guide and hoisting cable. The input pinion is integrated onto the motor shaft. as damage to this surface will prevent the gasket from sealing properly. 5-9. vertically split. An oil seal housed in the gear case at the motor input seals the motor shaft as it passes into the gear case. WARNING If output shaft assembly is pulled out of the gear case with the cover. anytime the motor is removed. INSPECTION OF HOIST GEARING a) General. If needed. As the cover is removed. (230 N-m) and the "C" and "D" Frame drum mounting bolts to 325 ft-lbs. Paragraph 4-2. A helical gear train provides smooth and quiet hoisting operation. (see Figure 5-6). make sure to apply a liberal amount of SG (Paragraph 4-7) spline grease to both the output shaft and drum splines. These bolts will be supporting the gearcase after the cover is removed. e) The hardware attaching the drum frame to the hoist and trolley frame may then be removed. splash lubricated.c. Gearcase. ensure that all gear and shaft assemblies remain in the case and are fully supported by the gearcase bearings. c) Remove the hoist from the beam. All pinions are integral with their shafts while the gears are keyed and pressed onto their shafts. cast aluminum case and cover. Paragraph 4-2. Do not tip or move the motor from side to side. as the spacing between bearings will be reduced. and the "D" Frame hoist assembly weighs 120 lbs. and the "D" Frame motor weighs 245 lbs. remove the hardware fastening it to the gear case. Torque is generated by compressing a friction disk between the stationary motor end bell and the spring loaded brake armature. Paragraph 5-8. (1) Lower hook block to the floor and relieve all load from ropes. (5) Provide a means to support the hoist motor. (8) Inspect all gears. The hoist brake is an electro magnetically released. (7) Replace the motor shaft seal using an appropriate seal driver. or mechanical damage. Fasten the motor to the gear case. Paragraph 4-2. See Section V. Coat the seal lip and the motor shaft with MPG grease. the compression springs push the armature against the friction disk and the other side of the friction disk against the motor end bell generating the torque necessary to stop the hoist machinery and hold the load. The friction disk is fixed to and rotates with the motor shaft. The friction disk is carried by a splined hub that permits axial movement when the brake is released. There is no torque adjustment of the brake. This axial movement releases both sides of the friction disk from their mating stationary surfaces and allows the friction disk to rotate freely when the brake is energized. Replace as necessary. 5-10. IMPORTANT! (8) Before reinstalling the motor.. It is recommended that gears and pinions only be replaced as sets. Severe damage to the hoist will occur if no gasket or the wrong gasket is used. The "B" Frame motor weighs 95 lbs. Page 18 . and the output shaft spline for wear. INSPECTION OF MOTOR BRAKE AND ACTUATING MECHANISM (1) (Except Motor 333273) (see 5-10 (2) 7½ hp) a) G eneral Operation. (10) Reconnect the conduit and power leads to the motor See Section VIII and refer to the specific wiring diagrams shipped with your hoist. See Section IX. Use a new gasket Do not attempt to assemble the cover to the gear case without a gasket. the armature plate is pulled across the air gap. (6) Once the motor is properly supported. Paragraph 4-2 before use. (11) Refill gear case with lubricant per Section IV. WARNING Failure to use a factory replacement seal will cause premature seal failure due to specific lip material requirements that must be met. Carefully withdraw the motor horizontally straight out from the gear case. (4) Disconnect the wiring and conduit from the motor junction box. (3) Drain the oil from the gear case per Section IV. pinions. (2) Make sure power to hoist is off and locked out. Thoroughly clean the output shaft external spline teeth before reassembly. can the output shaft assembly be safely removed from the gearcase. bearings. The "B" Frame gear assembly weighs 27 lbs. (9) Assembly is opposite of removal. Figure 9-2 for replacement parts. pack the gear teeth with MPG grease (Paragraph 4-7) and wrap the gear teeth with a number of layers of Teflon tape to protect the seal lip from being damaged by the gear teeth. the "C" Frame motor weighs 175 lbs. Friction disk wear can only be compensated for by resetting air gap. When power is removed from the magnetic coil. The motor shaft must remain horizontal and not rock up and down or side-to-side while installing the motor or seal damage will occur. Refill gear case with new lubricant per Section IV. as it is heavy. Paragraph 5-14. (9) Install the motor to the gear case. The motor must be adequately supported and held horizontally while removing and installing. Provide an adequate means to support this shaft and gear assembly before removing. the "C" Frame gear assembly weighs 55 lbs. It may be necessary to rotate the rope drum slightly to align the gear teeth to mesh with the teeth on the motor shaft. (6) If it is necessary to remove the output shaft assembly from the gear case. Using SG (Paragraph 4-7). Paragraph 5-14 to ensure proper lubrication. spring set non-adjustable brake. Ensure that the motor seats properly into the rabbet fit machined in the gear case. (12) Test hoist to ensure proper operation per Section V. The motor shaft must be in line with the seal bore and perpendicular to the mounting surface before attempting to insert the shaft through the seal. Only once the output shaft is free of the rope drum. the rope drum must first be removed from the hoist. When the magnet coil is energized. pitting.. WARNING The hoist must be removed from service and repaired on the ground for any maintenance that requires removal of the output shaft assembly or drum. grease the spline teeth on the output shaft before reinstalling rope drum. (7) The pinion shaft and gear assemblies may be removed as necessary. It will be necessary to compensate for the friction disk wear when a greater amount of hook movement (drift) is noticed when stopping. (10) Test hoist per Section V. Hoist Motor. It is recommended that a new seal be installed each time the motor is removed from the case. reassemble the brake body to the motor end bell and torque the mounting bolts to the value shown in Table 5-1. Measure the air gap at a minimum of three places around the circumference. (4) Carefully roll the large O-ring from the groove over the air gap back toward the magnet body. Measure friction disk thickness and replace if less than the minimum thickness shown in Table 5-1.472 in. Remove the snap ring in front of where the fan was mounted. (10 Nm) 0.035 in. . (2) Make sure power to the hoist is off and locked out. Motor Brake (Except 333273) b) Friction Disk Inspection and Air Gap Adjustment.027 in.016 in. The friction disk must slide on the splined hub and seat against the end bell of the motor. (6) Remove the three mounting bolts that attach the brake body to the motor end bell and remove the brake body from the motor. Paragraph 5-14 to ensure proper brake operation. d) Brake Re-assembly. as necessary. (25 Nm) 0.374 in.0 mm) Table 5-1. (1) Install the friction disk on the splined hub. c) Brake Disassembly.016 in. Repeat this step. Torque the mounting bolts to the values shown in Table 5-1. Replace all damaged or worn components as necessary. (5) Measure the air gap using feeler gages. before removing fan shroud.4 mm) 0. 9. (9) Test hoist per Section V. Remove the three (3) brake mounting bolts and draw the brake body away from the friction disk.5 mm) "C" & "D" Frame 18 ft-lbs. Ensure Page 19 Figure 5-8a. Install the large O-ring in the groove over the air gap. Do not excessively stretch this O-ring. (8) R eplace the large O-ring over the air gap and reassemble the fan shroud to the motor. (9. Whenever the friction disk is replaced. it is necessary to remove the brake body from the motor end bell. WARNING Check to be certain main power switch is locked in open position (OFF). (6) To measure the thickness of the friction disk. it is necessary to reset the air gap. (2) Install the brake body to the motor end bell using the three (3) mounting bolts. the air gap must be reset. See Figure 5-8. (12. Carefully set the brake body down on the motor shaft directly in front of the fan. (1) Lower hook block to the floor and relieve all load from ropes. Turn the hollow spacer bolts into the magnet body approximately 1/4 turn.4 mm) 0. (0.5 ft-lbs. (3) Remove the four (4) bolts attaching the fan shroud to the motor and remove the fan shroud. Remove the friction disk from the motor shaft. Draw the friction disk away from the end bell and measure the thickness across the friction surfaces.b. Retighten all three mounting screws. (7) Clean and inspect all components and working surfaces. it must be replaced. (5) Disconnect the two wires from the terminal block on the magnetic body. (4) Remove the snap ring behind the plastic fan. (0. (0.5 mm) 0. If the air gap exceeds the maximum value shown in Table 5-1. See Figure 5-8. (1) Lower hook block to the floor and relieve all load from ropes.7 mm) 0. Paragraph 5-10. until the required air gap is achieved. Figure 9-8. The air gap must be the same all the way around the brake. while backing these spacer bolts out of the magnet body will increase the air gap. (3) Remove the four (4) bolts attaching the fan shroud to the motor and remove the fan shroud. The air gap must be reset as described in Section V. torque the mounting bolts to the value shown in Table 5-1. Once the air gap is correct. If the friction disk thickness is less than the minimum shown in Table 1.Hoist Mounting Bolt Torque Nominal Air Gap Maximum Air Gap Minimum Brake Disk Thickness "B" Frame 7. See Section IX. Motor Brake Data (7) To reset the air gap. begin by releasing the (3) mounting bolts 1/2 turn. Carefully remove the fan and key from the motor shaft. (2) Make sure power to the hoist is off and locked out. Threading the hollow spacer bolts into the magnet body will decrease the air gap. If the friction disk thickness is within the allowable. As a result of normal wear of the brake disc lining. in particular the brake disc (23. Please note that Page 20 Brake Disc Replacement. 45 for BAPV) and the brake adjusters (19. (3) Connect the brake leads to the terminal block on the brake body. remove the nuts (20-21) and the springs (18). we recommend however to replace them at least every 18 months. Never exceed the maximum braking torque value stated on the motor name plate.8 16 mm Figure 5-8b. Air Gap H Dimension . Motor Brake (333273) a) General Operation. Install the rear retaining ring. Braking Torque Adjustment. The compression of the springs must be as uniform as possible. follow the instructions given into the paragraph "Air Gap Adjustment". When the magnet coil is energized. The hoist brake is an electro magnetically released. Check the wear on both friction surfaces of the brake disc (on one side only for BAPV series) to be sure that their thickness is not less than 2 mm. verify the exact air gap adjustment and if this inconvenience still persists. Verify that all motor and brake supply terminals are properly tightened to the terminal board as well as the earthing terminal to the motor frame. Take off the brake coil (25) from the brake adjusters (19). spring set adjustable brake. Verify regularly the brake adjuster (19-42) wear conditions and their steady fastening on the rear cover brake surface (17). The brake torque is proportional to the spring (18) compression. This axial movement releases both sides of the friction disk from their mating stationary surfaces and allows the friction disk to rotate freely when the brake is energized. Friction disk wear can only be compensated for by resetting air gap. Loosen the rear nut (27). Please verify that the braking torque is suitable for your application. refer to the paragraph "Brake Disc" Replacement"). remove the end cover (26) and unscrew the locknuts (22). All brake assembly components.. exactly where the disc slides. Paragraph 5-14. proceed backwards. (2) (Motor 333273 7½ hp) the brake linings wear is greater during the run-in. For the air gap adjustment. The replacement frequency comes from the motor duty (number of start/stop. Remove the brake moving element (24) sliding it through the brake adjusters (19). When power is removed from the magnetic coil. in the hub toothing. Install the fan shroud and bolts. applied moment of inertia. (4) Install the forward fan mounting retaining ring and install the fan. Take off the old brake disc (23) and put in the new one. proceed to its adjustment as stated in the paragraph "Braking Torque Adjustment".this O-ring is not pinched in the air gap. 39-41 for BAF series.4 . If the brake coil (25) is not able to call the brake moving element (24) back with a quick stroke and keep it attracted without vibrations. For those brake disc with rivets on disc lining verify that braking surface has not reached the rivets. In the BAF series . environment conditions and so on). It will be necessary to compensate for the friction disk wear when a greater amount of hook movement (drift) is noticed when stopping. Periodically check and verify the shaft splines wear. Verify also that there are no damages on disc surfaces and in particular. 42 for BAF-BAPV series) are subject to wear. There is no torque adjustment of the brake. After every intervention pls verify that the braking torque is required. If needed. Torque is generated by compressing a friction disk between the stationary motor end bell and the spring loaded brake armature. The friction disk is fixed to and rotates with the motor shaft. moreover check that no play should be between the brake disc and the brake disc hub in correspondence of the hub nails. The corresponding brake torque of the standard compression values stated on the table are less than the maximum braking torque stated on the motor nameplate. (5) Test hoist per Section V. For reassembling. (For replacement. The friction disk is carried by a splined hub that permits axial movement when the brake is released. We recommend that the new brake disc must be handled with clean hands. because even a small trace of grease will decrease the braking performance and also increase noise. the compression springs push the armature against the friction disk and the other side of the friction disk against the motor end bell generating the torque necessary to stop the hoist machinery and hold the load. loosen the locknut (20) and try it again until desired functioning is obtained. It's recommended to avoid adjusting the braking torque to values lower than 30% of the maximum value. On the table 2 and 3 are shown the standard compression values (H std) of the brake springs. the armature plate is pulled across the air gap. check that the air gap does not exceed the values shown on table 1. In consideration of safety it's needed to replace them periodically. especially for AC brake assembly. Verify periodically that the raking torque is suitable. (few thousands stops). e. Proceed with the air gap adjustment as stated in the respective paragraph. when the brake is energized. A spacer washer between the cross shaft bearings and the pinion aligns the gear mesh. This wrong operation could stress the air gap adjusters. follow up the specific instructions. If adjustment is necessary. verify that the air gap is uniform and the nuts (21-22) are tightened. verify that the cross shaft surface is free of mechanical damage and oil before tightening the setscrews. operate on the nuts (21-22) to obtain the brake coil forward displacement towards the brake moving element (24). Loosen the rear nut (27). Pay attention to place the electrical connectors in the right position so that to allow their insertion. For brake assembly with 6 brake adjusters (19. It's strongly unadvisable to exceed these values in order to avoid vibrations of the brake moving element. In case of any vibration.otherwise than in the BA series there are 2 brake discs (39-41) with an intermediate brake moving element (40) in between. Replace all damaged or missing items. Check for adequate lubrication (WG. remove the end cover (26). The pinions are held in place by means of locking setscrews. remove setscrews. Reassemble the new brake coil on the brake adjusters (19) and reconnect the electrical connectors. c) Inspect wheel treads. because the wear of the brake disc linings. The air gap *90) i. carried directly by the hoist frame. remove leftover locking patch. Brake Coil Replacement. The air gap must be uniform to guarantee the right working and avoid mechanical stresses due to a wrong alignment. Before reassemble the end cover (26) and the nuts verify that the connections and relative cables are properly tightened. After having adjusted the position on these 3 brake adjusters. the distance between the two magnetic cores of the brake coil (25) and the brake moving element (24). Check wheel bearings for any signs of wear. it tends to increase. It's advisable to check periodically the air gap. and cross shaft bearings. Failure to do so may allow the drive shaft to contact the hoist gearcase. d) Examine the drive pinions. cross shaft. Drive pinions must be replaced as sets and should be replaced along with the drive wheels. CAUTION Ensure that the cross shaft is properly positioned and locked into place by means of the setscrews. Please verify that the air gap is uniform. including rough rotation and signs of lubricant leakage. Proper clearance must exist along the entire length of beam that the hoist can traverse. For the flywheel (45) replacement on the BAPV series. flanges. Section IV. check that terminal connectors are coupled correctly and tightly. Air Gap Adjustment. These wheels rotate on sealed ball bearings supported by fixed pins. It's strongly recommended to avoid to tighten the locknut (22) located on one brake adjuster (19. Pinions drive two opposing wheels with gear teeth cut into the flange. The drive shaft passes through one hoist side and is keyed to and driven by a single reduction hollow shaft gear reducer. Wheels must always be changed in opposing pairs and drive wheels should be changed when the drive pinions are replaced. the brake coil (25) should attract the brake moving element (24) with a quick stroke. adjust trolley per Section II. Paragraph 4-7) on the wheel gear and pinion mesh. Both pinions are mounted on a keyed drive shaft supported by sealed ball bearings at each hoist side. An amount of 3/32 to 1/8 inch clearance per side is recommended for a total of 3/16 to 1/4 inch wider than the beam flange. When the operations has been settled. 42 for BAPVBAF series motors). After the brake coil (25) replacement. Paragraph 2-2. as first step regulate the brake coil position only on three brake adjusters at 120 by the nuts 21-22. prominent noise. and reassemble using a thread locking compound such as Loctite 242. The hoist must be centered on the beam with clearance between the sides of the bottom of the beam flange and the inside faces of the wheel flanges. 42 for BAPV-BAF series motors). If too little or too much clearance is determined. Check pinions for gear tooth wear and proper alignment with wheel gear. and gear teeth for wear. the locknuts (22) should be tightened. two on each side of the beam. must be as shown on table 1. 42 for BAPV-BAF series motors) before having completed the positioning of the brake coil (25) on all the brake adjusters. Therefore don't regulate the position of the brake coil adjusting the nut (21) on one brake adjuster. When the air gap adjustment has been settled. If it is necessary to adjust or reset the pinions. Unscrew the locknuts (22) and pull off the brake coil (25) from brake adjusters (19). disconnect the brake coil (25). The cross shaft bearings are sealed for life and should be replaced at any sign of mechanical wear or lubricant leakage. Verify that the brake coil functions correctly. 5-11. proceed to the air gap adjustment (see the pertinent paragraph). if previously you didn't loose the locknuts (22) on all the brake adjusters (19. to complete the operation go on with the other 3 brake adjusters and first bring the air gap adjusting nuts (21) close to the brake coil and then tighten the locknuts (22). The traverse drive consists of four single flange wheels. Traverse Drive Arrangement ("B" & "C" Frame Shown) a) General. and hold it without any vibration or noise. Setscrews hold the pinions and spacer washers tight against the bearings. Verify that the setscrews are tight on the cross shaft. In order to set the air gap back to the required value. the burning of the brake coil or the brake assembly damaging. INSPECTION OF HOIST TRAVERSE DRIVE Figure 5-9. b) Ensure that the hoist is properly fitted to the beam. Page 21 . Please note that the brake linings wear is greater during the run-in (few thousand stops). and this manual. (3) Depress "DN" push button. Series Lifting Equipment. mechanical damage or lubricant leaks. TESTING BLOCK OPERATED LIMIT SWITCH a) General. the geared limit switch must be reconnected and tested. hoist should stop immediately and hold load at that level. To test. Do not rotate the adjustment discs. NOTE: If load drifts downward slowly in step 2 or 3 above. Damage can be avoided by immediately releasing the pushbutton once the lower block has traveled through the limit switch weight. without load. 5-13. b) Procedure. lower load a short distance and release button. CAUTION Damage to the hoist may occur if the block operated limit switch fails during testing. SECTION VI . Position the lower block three inches (3") below the point where the block operated limit switch is activated. b) Check hoist as outlined in PRE-OPERATION CHECKS. The rotary-geared limit switch (screw type limit switch) is the primary upper limit switch and must be temporarily bypassed to allow the block operated limit switch to be tested. hoist should be tested to insure safe operation. The geared limit switch must then be tested. immediately release the pushbutton before damage to your hoist occurs. Ensure that the geared limit switch stopped the hoist before the block operated limit switch was activated. Test the geared limit switch by raising the lower block until it stops. SEVERE DAMAGE AND/OR A DROPPED LOAD COULD RESULT. see Section VII. Remove load from the hook. TESTING HOIST a) General. refer to Figure 7-2. c) Check hoist with rated load. However. suspend hoist from an overhead supporting member of sufficient strength to support the weight of the hoist and the rated load. e) Inspect the traverse gearbox and motor. . This device is preset at the time of hoist inspection to prevent the lifting of loads weighing 125-150% of rated capacity. If the block operated switch functions properly. before contacting the factory. This section contains possible causes and solutions to common hoist problems. SECTION II. Hoist should stop immediately and hold load at that level. then the switch setting is correct. TESTING OVER-CAPACITY LIMIT SWITCH The over-capacity limit switch is provided as standard equipment on SHAW-BOX "World Series" hoists. Please attempt to remedy your hoist problems by following these steps.SECTION VII. motor brake requires adjustment . when hoist has been disassembled and reassembled. Look for signs of rough operation. Replace and tighten as necessary. Allow 3" for hook drift in both directions. namely Section 9. Inspect the hollow bore and keyed cross shaft for wear. Allow the locking plate to slide down and disengage from the adjustment discs.811 "Specification for rope and chain hoists". When push button is released.see Motor Brake Adjustment . Whenever servicing electrical components. Never allow less than two (2) complete wraps of rope on drum with hook in lowest position. If misadjusted. The block operated limit switch may now be tested by slowly and carefully raising the hook until the limit switch rod contacts the lower block. The optional block operated limit switch is a secondary upper limit switch actuated when the lower block contacts the actuator rod. Testing shall be performed in accordance with FEM Section IX. before placing hoist in service. WARNING Check limit switch operation carefully. Paragraph 2-4. (See Figure 7-2). Verify that all bolts that hold the gearbox to the trolley frame (and torque arm) and the four bolts that hold traverse motor to the gearbox are all present and tight. (2) Depress "UP" push button and raise load. To disconnect the geared limit switch. Paragraph 7-3 for adjusting the geared limit switch. Refer to SECTION VII. Replace geared limit switch cover when testing and adjusting is complete. If hoist is capable of lifting the load. Remove the limit switch cover then loosen the two (2) screws holding the locking plate in place.TROUBLESHOOTING 6-1. Connect hoist to power supply as shown on hoist nameplate and perform the checks listed in b) and c) below. apply 125% of the rated capacity to load hook. 5-14. Before placing hoist in service. (1) Attach rated load to lower hook. If this is not the case. The geared limit switch shall be reconnected by sliding the locking plate back into position ensuring slots on adjustment discs are fully engaged and tightening locking plate screws to 4 in-lbs. Once it has been determined that the block operated limit switch is functioning properly. be sure to shut off and lock out power following proper lockout/tagout procedures. If hoist cannot lift load. Page 22 WARNING Working in or near exposed energized electrical equipment presents the danger of electric shock. Paragraph 7-1. To test the function of the over-capacity limit switch. The factory recommends complete replacement of the traverse gearbox. TO AVOID INJURY: DISCONNECT POWER AND IMPLEMENT LOCKOUT/ TAGOUT PROCEDURE BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT. If the hook does not stop when the limit switch rod is lifted. 5-12. then actual switch setting may be higher than necessary and needs to be adjusted. proceed by testing in the same manner with rated load on the hook. GENERAL. This switch is integral to the wire rope dead end assembly and is factory preset to prevent over-capacity lifts. Paragraph 7-4 for information regarding the adjustment of the limit switch setting. gearbox service may be available from your local authorized SHAWBOX repair center. replace contactor. down button inoperative 6-5. See that necessary jumper wires are properly installed. Check phase protection device (PPD). replace contactor. Hoist Will Not Operate b. See that necessary jumper wires are properly installed on contactor. a. No control voltage f. replace contactor. Trouble SECTION Vl . b. Verify that the contactor armatures are free to move. Hoist electrical circuit open c. a. Reverse phasing on three phase hoists b. Check transformer fuse. Contactor assembly not functioning d. If binding occurs. d. Wrong voltage c. e. If blown. Hook Will Raise But Not Lower a. c. a. Hoist Will Not Lift Rated Load a. remove electrical cover on hoist and check wiring connections. Check wiring connections with appropriate wiring diagram. See that necessary jumper wires are properly installed on contactor. b. Check input power supply. Motor burned out g. Check hoist motor connections. if amber LED is steady. No power to hoist Remedy a. Shut off and lock out power supply. Check switches. Also check connections in push button station and limit switches. Check hoist motor connections. interchange any two power supply line leads per Section II. Check power collectors. Down. Loose or broken wire connections in hoist electrical system d. interchange any two sets (each winding) of motor power leads. Check PPD. Paragraph 2-4. Check push button contacts and wires. Lower electrical circuit open b. If binding occurs. Check for loose connections. g. Verify that the contactor armatures are free to move.b. Reverse phasing on three phase hoists 6-2. Verify the transformer secondary is the same voltage as the coils to which it is connected. f. Check for burned out contactor coils. a. Hoist wired incorrectly 6-3. Contactor assembly not functioning e. Replace motor. Check size of power supply lines. Check for burned out contactor coils. Contactor assembly not functioning c. Check the transformer coil for signs of overheating. b. circuit breakers or fuses and connections in power supply lines. push button inoperative 6-4. b. Page 23 6-1. Verify that the contactor armatures are free to move. Up. check for grounding and/or shorts in the push button station.TROUBLESHOOTING Probable Cause a. Check push button contacts and wires. Replace transformer if burned out. Check for burned out contactor coils. Hook Moves in Wrong Direction a. if green LED is steady. c. See that necessary jumper wires are properly installed. Check voltage required on motor data plate against power supply. as shown on nameplate. d. See that necessary jumper wires are properly installed. Excessive load b. See that power supply current is the same voltage Iisted on motor data plate. Reduce loading to rated load of hoist. Hook Will Lower But Not Raise a. If binding occurs. c. Low voltage . Check for loose connections. Loose connections SECTION VII . a. inspect motor brake (Section V. BLOCK OPERATED LIMIT SWITCH ADJUSTMENT. furnished as optional equipment. This limit switch has a rotary screw driven by a gear reduction that is coupled to the end of the drum shaft. a. d. the motor brake mayrequire adjustment to compensate for brake disc wear. Excessive load b. . repeat as needed until switch functions properly. Paragraph 5-10. Hoist Motor Overheats d. Collectors make poor contact b. WARNING Check to be certain main power switch is locked in open position (OFF) before removing brake cover. Reduce loading to rated load. Check hoist and inspect for defective. loosen the limit switch hub retaining screw and rotate the hub and rod downward to ensure earlier contact. With No Load. Trouble SECTION Vl . e. b. Instructions for adjusting limit switch are inside cover and are repeated below (see Figure 7-2). Wrong voltage or frequency Remedy a. The geared rotary type limit switch is standard equipment and is located on the drum end opposite the gearcase end. Adjustment discs operate the contacts of separate switches. Disassemble hoist and inspect for defective. b. Check collectors for free movement of spring arm.TROUBLESHOOTING Probable Cause a. Motor brake not holding 6-8. Retighten and test. 7-3. paragraph 7-1. check hoist for drift. Screw-Type Limit Switch Adjustment (Wires Not Shown for Clarity. paragraph 5-10) and adjust as outlined in Section VII. which is shipped with the hoist. the load hook "drifts" downward more than usual for your hoist before coming to a stop. Defective motor or worn bearings in hoist frame e. If the block switch is not tripping after contact with the lower block body. is minimally adjustable and designed to stop the lower block at the safest high point of travel to eliminate any possibility of double-blocking.) a) Remove four screws and lift off switch cover. as shown on nameplate. Check current rating on motor data plate against power supply. When the safest high point is reached. 7-2. The block operated limit stop. Hoist Operates Intermittently a. weak spring or electrical connections. b. Paragraph 7-1. The switch assembly must be wired in accordance with the appropriate wiring diagram. the limit switch automatically stops hook travel. Reduce loading to rated load as shown on nameplate. c. Excessive duty-cycle c. WARNING Be certain that electrical power supply is OFF and locked in the open position before removing limit switch cover.ADJUSTMENTS 7-1. Refer to Figure 5-8 and proceed as outlined in Section V. These brakes are designed so that adjustment is seldom required. If. one for the hoisting Page 24 12758B Switch Locking Adjustment Discs Switch Plate Figure 7-2. worn or damaged parts. Check all wiring for loose connections. MOTOR BRAKE ADJUSTMENT . 6-6. If drifting is excessive. after a period of service. Brake not adjusted properly 6-7. Reduce frequency of lifts or amount of jogging. GEARED ROTARY LIMIT SWITCH ADJUSTMENT. worn or damaged parts. Load Drifts Excessively When Hoist Is Stopped a. Adjust brake per Section VII. circuit and one for the lowering circuit. Excessive load b. Over-Capacity Limit Switch ("B" & "C" Frame) . f) Carefully check limit switch operation without load before placing hoist in service. WARNING Be certain that electrical power supply is OFF and locked in the open position before attempting shortening of push button cable. The limit switch is factory preset to prevent the lifting of loads weighing 125-150% of rated capacity.WIRING DIAGRAMS 8-1. WARNING Check limit switch operation carefully. However. Never allow less than two (2) complete wraps of rope on drum with hook in lowest position. Allow 3" for hook drift in both directions. Never allow less than two (2) complete wraps of rope on drum with hook in lowest position. d) Slide locking plate back into position ensuring slots on adjustment discs are fully engaged. Figure 7-3b. Page 25 Figure 7-3a. a) Loosen screws at cable connectors and clamps at top of cable. At times. it may be necessary to adjust the limit switch setting. Allow 3" for hook drift in both directions. Figures 8-1 and 8-2 are examples of typical two-speed hoist and trolley wiring diagrams respectively. GENERAL. e) Replace cover. tighten locking plate screws to 4 in-lbs. Over-Capacity Limit Switch ("D" Frame) To adjust the limit switch setting. repeat steps above. left for down toward switch to reduce hook travel or away from switch to increase hook travel. e) Strip cable sheath and connect wires with the same type of terminals previously furnished (care must be taken to match previous wire color coding with wire markers in accordance with the wiring diagram furnished with the hoist). without load. We suggest you carefully file the wiring diagram with this book for future reference. b) Adjust steel support cable to proper length and tighten screws. & 7-3b. If misadjusted. A print of the correct wiring diagram for each hoist is furnished as a separate insert and shipped with the hoist. Loosening the adjustment bolt will reduce the load required to trip the limit switch plunger while tightening will increase this setting. If misadjusted. before placing hoist in service. Slide locking plate away from adjustment disc. OVER-CAPACITY LIMIT SWITCH ADJUSTMENT. SECTION VIII . d) Tighten cable grip and cut off excess cable. Adjusting the limit switch setting to increase the capacity limit beyond 125% is not permitted. This is due to different currents and types of electrical components used in their construction. b) Loosen locking plate screws. simply loosen the locking nut(s) (see Figures 7-3a & 7-3b) and then either loosen or tighten the adjustment bolt into the overload beam to achieve the desired setting. Only very small adjustment is required. c) Turn proper adjustment disc (right for up. The over-capacity limit switch is standard equipment and is integrated into the wire rope dead end assembly (see Figures 7-3a. The device is designed to prevent over-loading of the equipment. but is not intended to be used as a load-measuring device.). SEVERE DAMAGE AND/OR A DROPPED LOAD COULD RESULT. 7-4. please consult the exact wiring diagrams for your hoist. c) Loosen upper cable grip and pull excess cable into connection box at hoist. 7-5. SHORTENING OF PUSHBUTTON CABLE Provide a light film of MPG grease (Paragraph 4-7) on gear of both limit switches. Comprehensive wiring diagrams for SHAWBOX electric hoists have been omitted from this book because of the many possible variations. Figure 8-1. Elementary Wiring Diagram for a Two-Speed Hoist and Trolley with Standard Features Page 26 . Component Diagram for a Two-Speed Hoist and Trolley with Standard Features Page 27 .Figure 8-2. Motor. Gearcase. To determine the size of your hoist. The "B" Frame measures 9-3/4" wide and requires approximately 5 quarts of oil. Rope Guide. The "D" Frame measures 17" and requires approximately 12 quarts of oil. A typical hoist is shown as the basis for the exploded parts illustrations. It is suggested that these parts be purchased for your hoist as spares for future use. Voltage. These parts are listed at the end of this manual. 9-1a. and Limit Switch Hoist Gearing Motor Driven Trolley Frame and Drive Lower Block Assembly Upper Block Assembly Wire Rope Dead End Assembly with Limit Switch Rope Guide Assembly Hoist Motor Brake – Standard Service Hoist Motor Brake – Outdoor Service FIGURE No. The parts lists and illustrations in this section of the manual cover parts for models of SHAW-BOX "World Series" Electric hoists. therefore. always give the Hoist Serial Number. The "C" Frame measures 12-1/2" and requires approximately 11 quarts of oil. WARNING Using "Commercial" or other manufacturer's parts to repair World Series Hoists may cause load loss. Certain parts of your hoist will. 9-6b 9-7a. LIST OF PART ILLUSTRATIONS TITLE Hoist Drum. measure the width of hoist gearcase (see Figure 4-2). ALWAYS INCLUDE MODEL AND SERIAL NUMBER ON ORDER. SHAW-BOX "World Series" hoists are built in three basic frame sizes. Some of these itemized parts are not for individual sale. GENERAL. Phase. Motor Horsepower. Parts may look alike but SHAW-BOX Hoist parts are made of specific materials or processed to achieve specific properties. For this reason.SECTION IX . "C" and "D" Frame. WHEN ORDERING PARTS OR INFORMATION ON THIS EQUIPMENT. Frequency and Capacity of Hoist when ordering parts. but must be grouped with other related replacement items. 28 33 36 40 42 44 47 49 51 Notes Page 28 . require replacement under normal wear conditions.PARTS LIST 9-1. Drum Frame. TO AVOID INJURY: Use only SHAW-BOX Hoist supplied parts. "B". The numbers assigned to parts of our various assemblies in our Parts List are the part numbers used in manufacturing. 9-1b 9-2 9-3 9-4 9-5 9-6a. in time. Catalog Number. certain variations may occur from the information given. 9-7b 9-8 9-9 PAGE No. M12 Flat Washer. 60 Hertz. Rope Guide and Screw Type Limit Switch "B" Frame: Hoist Components for Figure 9-1a. M16 Socket Head Cap Screw. 3-phase. 60 Hertz 460 volt. 25' Lift Model Rope Drum. Gearcase. M16 High Strength Flat Washer. 3-phase. 40' Lift Model Rope Clamp Socket Head Cap Screw. 3 phase. M12 Hex Head Bolt. M8 Hi-Collar Lockwasher. 25' Lift Model Frame Rod. 60 Hertz. Drum Frame. M8 Qty. 3 phase. (continued on next page) Page 29 . 40' Lift Model Rope Drum Rope Drum. M12 Hex Head Bolt. Ref. Req’d 1 1 - 33313801 33313802 33313803 33327303 33313804 33294001 33294002 33294003 33294004 2 N/A 3 N/A 4 N/A 5 44933001 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 - 23385901 23385902 17 - 44931501 44931502 18 23380301 19 N/A 20 N/A 2 2 4 1 4 4 4 2 2 4 8 4 2 2 1 1 3 3 3 *Note: The "B" Frame.5 HP Hoist Motor. 60 Hertz 230 volt.Figure 9-1a. Motor. Outdoor Service 460 volt. 2-Speed with Brake and Fan (See Figure 9-8 for Parts) 208 volt. Outdoor Service 230 volt. Outdoor Service 575 volt. No. 60 Hertz. Hoist Drum. 3-phase. M12 Flat Washer. (MGM)* 575 volt. M10 Hi-Collar Lockwasher. Outdoor Service Hex Head Bolt. 60 Hertz. 3 phase. 60 Hertz 460 volt. M12 Hoist Gearcase (See Figure 9-2 for Parts) Socket Head Cap Screw. M16 Locknut. M10 Drum Frame Rod Frame Rod. 7½ hp. Part Number Description 7. 3 phase. 3-phase. M12 Locknut. 460 volt motors come from 2 suppliers. M12 Locknut. M12 Lockwasher. 60 Hertz (ABM)* 208 volt. M12 Locknut."B" Frame: Hoist Components for Figure 9-1a. 60 Hertz 230 volt. M8 Drum Frame Bracket Flanged Cartridge Ball Bearing External Retaining Ring Limit Switch Bracket Hex Head Bolt (Short). No. M10 Hi-Collar Lockwasher. 3-phase. M10 Drum Frame Rod Frame Rod. M20 High Strength Flat Washer. 60 Hertz. 25' Lift Model Stiffener Plate. 60 Hertz. 60 Hertz 575 volt. Outdoor Service 575 volt. M20 Locknut. M12 Geared Limit Switch Drum Shaft Insert for Geared Limit Switch Stiffener Plate Stiffener Plate. 3 phase. 2-Speed with Brake and Fan (See Figure 9-8 for Parts) 208 volt. M16 (continued on next page) Page 30 Qty. M12 Hoist Gearcase (See Figure 9-2 for Parts) Socket Head Cap Screw. 40' Lift Model Rope Clamp Socket Head Cap Screw. 3 phase. 3-phase. M8 Hi-Collar Lockwasher. 3 phase. 40' Lift Model Rope Drum Rope Drum. Part Number Description 15 HP Hoist Motor. Ref. Ref. Outdoor Service 460 volt. M10 Locknut. 25' Lift Model Rope Drum. Part Number Description Drum Frame Bracket Flanged Cartridge Ball Bearing Heavy Duty External Retaining Ring Limit Switch Bracket Hex Head Bolt (Short). M12 Hex Head Bolt (Long). 60 Hertz 208 volt. M20 Socket Head Cap Screw. 3-phase. Outdoor Service Hex Head Bolt. M16 Locknut. 3 phase. M12 Hex Head Bolt. 25' Lift Model Frame Rod. 60 Hertz. 60 Hertz 460 volt. Req’d 2 1 1 1 2 2 4 1 1 2 8 8 1 1 1 21 33291102 22 11801803 23 11802401 24 23383801 25 N/A 26 N/A 27 N/A 28 43981305 29 11593901 30 - N/A N/A 31 N/A 32 N/A 33 44931801C 34 NO12283 35 44930801 "C" Frame: Hoist Components for Figure 9-1a. M12 Lockwasher. 3-phase. 60 Hertz. Req’d 1 1 - 33314001 33314002 33314003 33314004 33294101 33294102 33294103 33294104 2 N/A 3 N/A 4 N/A 5 44935501 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 - 23387601 23387602 17 - 44933501 44933502 18 23380301 19 N/A 20 N/A 21 33291702 22 11801802 23 10119421 24 23383801 25 N/A 2 2 4 1 4 4 4 2 2 4 8 4 2 2 1 1 3 3 3 2 1 1 1 2 . M16 Hex Head Bolt. M12 Flat Washer. M12 Lockwasher. No. 40' Lift Model Socket Head Cap Screw. Outdoor Service 230 volt. M16 Flat Washer. M10 Rope Guide (See Figure 9-7a for Parts) Hydraulic Fitting for Flanged Cartridge Ball Bearing (Not Shown) SHAW-BOX Brand Label for Gearcase (Not Shown) Qty. Part Number Description Hex Head Bolt (Long)."C" Frame: Hoist Components for Figure 9-1a. M10 Locknut. Ref. M16 Geared Limit Switch Drum Shaft Insert for Geared Limit Switch Stiffener Plate Stiffener Plate. 25' Lift Model Stiffener Plate. No. 40' Lift Model Socket Head Cap Screw. M16 Lockwasher. M10 Rope Guide (See Figure 9-7a for Parts) Hydraulic Fitting for Flanged Cartridge Ball Bearing (Not Shown) SHAW-BOX Brand Label for Gearcase (Not Shown) Qty. Req’d 2 4 1 1 2 8 8 1 1 1 26 N/A 27 N/A 28 43981305 29 11593901 30 - N/A N/A 31 N/A 32 N/A 33 44933801C 34 NO410 35 44934201 Notes Page 31 . 60 Hertz. M16 Hex Head Bolt. 2-Speed with Brake and Fan (See Figure 9-8 for Parts) 208 Volt. Outdoor Service 575 volt. M20 Hex Head Bolt. 40' Lift Model Rope Clamp (continued on next page) Page 32 Qty. M16 Flat Washer. 60 Hertz 575 Volt. Hoist Drum. Motor. Gearcase. M16 Lockwasher. 60 Hertz. 3-Phase. M20 Locknut. 25' Lift Model Frame Rod. M12 Locknut. Outdoor Service 460 volt.Figure 9-1b. 60 Hertz. 3 phase. 3-Phase. M20 High Strength Flat Washer. 3-Phase. 60 Hertz 230 Volt. M12 Flat Washer. 25' Lift Model Rope Drum. No. Drum Frame. 3 phase. 60 Hertz 208 volt. M16 Drum Frame Rod Frame Rod. 3 phase. Req’d 1 1 - 33292901 33292902 33292903 33292904 33294201 33294202 33294203 33294204 2 N/A 3 N/A 4 N/A 5 44936501 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 - 23394601 23394602 15 - 44936701 44936702 16 23332702 2 2 4 1 4 4 4 6 12 6 4 4 2 1 3 . M16 Locknut. Outdoor Service 230 volt. 3-Phase. Rope Guide and Screw Type Limit Switch "D" Frame: Hoist Components for Figure 9-1b. Ref. Outdoor Service Hex Head Bolt. 40' Lift Model Rope Drum Rope Drum. Part Number Description 20 HP Hoist Motor. 3 phase. M12 Hoist Gearcase (See Figure 9-2 for Parts) Socket Head Cap Screw. 60 Hertz. 60 Hertz 460 Volt. M10 Hi-Collar Lockwasher. M16 Lockwasher. M16 Geared Limit Switch Drum Shaft Insert for Geared Limit Switch Rope Guide Keeper Plate Hex Head Bolt. M16 Lockwasher. 25' Lift Model Guide Rod. Ref. M12 Hi-Collar Lockwasher. M12 Drum Frame Bracket Flanged Cartridge Ball Bearing Heavy Duty External Retaining Ring Limit Switch Bracket Hex Head Bolt. Req’d 3 3 2 1 1 1 4 4 1 1 1 2 2 1 1 1 1 1 17 N/A 18 N/A 19 33293301 20 11801804 21 11802402 22 23395201 23 N/A 24 N/A 25 43981305 26 11593901 27 N/A 28 N/A 29 N/A 30 N/A 31 N/A 32 - 23387603 23387604 33 33293401C 34 44937201 Notes Page 33 . 40' Lift Model Rope Guide (See Figure 9-7b for Parts) SHAW-BOX Brand Label for Gearcase (Not Shown) Qty. M10 Rope Guide Rod Guide Rod. Part Number Description Socket Head Cap Screw. No."D" Frame: Hoist Components for Figure 9-1b. M16 Socket Head Cap Screw. M8 Hi-Collar Lockwasher. Part Number Description Complete 5t Hoist Gearcase Ass'y. 24) Gearcase Gasket/Bearings Kit (Incl. Ref. Ref.80.57:1 Ratio Gearcase Gasket/Seal Kit (Incl. Nos. 3. Nos. 21. 8. 3. 24) Gearcase Cover Gasket Vent Plug Drain/Fill Level Plug Socket Head Cap Screw. 14. Ref. Req’d 1 1 1 1 1 2 12 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 44933001C 44933090 44933091 1 N/A 2 N/A 3 N/A 4 - 5 - 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 N/A 25 N/A 26 N/A Page 34 . 18. No. 23. 13. M12 Qty. 23. Hoist Gearing "B" Frame: Hoist Gearing for Figure 9-2. 19. .Figure 9-2. M8 Ball Bearing External Retaining Ring Intermediate Gear Drum Pinion Shaft Key Ball Bearing Ball Bearing Intermediate Pinion Shaft Key Motor Gear Ball Bearing Ball Bearing Output Shaft Roller Bearing Dowel Pin Motor Shaft Oil Seal Output Shaft Oil Seal Torque Pin Threaded Stud. M12 Hi-Collar Lockwasher. Nos. 24) Gearcase Cover Gasket Vent Plug Drain/Fill Level Plug Socket Head Cap Screw. 23. No. 24) Gearcase Gasket/Bearings Kit (Incl. 19. . Part Number Description Complete 10t Hoist Gearcase Ass'y. 13.103.8:1 Ratio Complete 7. 14. M12 Ball Bearing External Retaining Ring Intermediate Gear Drum Pinion Shaft Key Ball Bearing Ball Bearing Intermediate Pinion Shaft Key Motor Gear Ball Bearing Ball Bearing Output Shaft Roller Bearing Dowel Pin Motor Shaft Oil Seal Output Shaft Oil Seal Torque Pin Threaded Stud. M12 Qty. 8.103. Nos. 18.8:1 Ratio Gearcase Gasket/Seal Kit (Incl. Ref."C" Frame: Hoist Gearing for Figure 9-2.5t Hoist Gearcase Ass'y. 21. Ref. 3. 23. Ref. . Req’d 1 1 1 1 1 1 2 12 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 44935501C 44935501C 44935590 44935591 1 N/A 2 N/A 3 N/A 4 - 5 - 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 N/A 25 N/A 26 N/A Notes Page 35 . 3. 3.7:1 Ratio Gearcase Gasket/Seal Kit (Incl. M12 (not shown) Hi-Collar Lockwasher. M12 Socket Head Shoulder Screw. Ref. Ref. 23. M12 Qty. 18. 3. 8. 13.132. Req’d 1 1 1 1 1 2 10 2 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 Notes Page 36 . Nos. M12 Ball Bearing External Retaining Ring Intermediate Gear Drum Pinion Shaft Key Ball Bearing Ball Bearing Intermediate Pinion Shaft Key Motor Gear Ball Bearing Ball Bearing Output Shaft Roller Bearing Dowel Pin Motor Shaft Oil Seal Output Shaft Oil Seal Torque Pin Threaded Stud. No. 21. 19. Ref. 24) Gearcase Cover Gasket Vent Plug Drain/Fill Level Plug Socket Head Cap Screw. . Nos."D" Frame: Hoist Gearing for Figure 9-2. 1 2 3 4 5 6a 6b 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part Number Description 44936501C 44936590 44936591 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Complete 15t Hoist Gearcase Ass'y. 14. 24) Gearcase Gasket/Bearings Kit (Incl. 23. 12. 8 1/8" Thru 14" Trolley Beam Flange Width Alignment Bar. 15. Part Number Description Geared Wheel Assembly Pair (Incl. 14 1/8" Thru 20" Trolley Beam Flange Width Plain Hex Nut. Req’d 44931411 44931412 1 - N/A N/A 2 - N/A N/A 3 - N/A N/A 4 - 5 - 23384201 23384202 23384203 6 N/A 7 N/A 8 N/A 9 - N/A N/A N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 1 1 1 1 2 3 4 4 2 12 4 4 2 2 8 . 16. Nos. 16. of Speeds. Nos. 25' Lift Model Counterweight. 18) Trolley Frame Side Drum Side. Ref. "B" Frame: Trolley Frame and Drive Components for Figure 9-3. M16 Lockwasher. Ref. No. 40' Lift Model Hoist /Trolley Controls (Specify HP. M16 Wheel Axle Plain Trolley Wheel Geared Trolley Wheel Ball Bearing (continued on next page) Page 37 Qty. 12. 13. 40' Lift Model Trolley Frame Side Traverse Drive Side. No. 40' Lift Model Counterweight Plate Counterweight. 15. 25' Lift Model Drum Side. Frequency. 8 1/8" Thru 14" Trolley Beam Flange Width Threaded Rod. 14. Ref. M10 Threaded Rod. Voltage. M10 Lockwasher. 25' Lift Model Traverse Drive Side. M16 Threaded Rod. 14 1/8" Thru 20" Trolley Beam Flange Width Key Plate Socket Head Cap Screw. 4" Thru 8" Trolley Beam Flange Width Threaded Rod. 18) Plain Wheel Assembly Pair (Incl.Figure 9-3. 4" Thru 8" Trolley Beam Flange Width Alignment Bar. 17. Options) Alignment Bar Alignment Bar. 17. Motor Driven Trolley Frame and Drive ("C" Frame Shown). M20 Lockwasher. Nos. 40' Lift Model Trolley Frame Side Traverse Drive Side. M16 Hex Head Bolt. M10 Flat Washer. 14 1/8" Thru 20" Trolley Beam Flange Width Key Plate Socket Head Cap Screw. Options) Alignment Bar Alignment Bar. 8 1/8" Thru 14" Trolley Beam Flange Width Threaded Rod. Req’d 4 4 4 2 2 2 2 4 1 16 N/A 17 N/A 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 - N/A N/A N/A 25 N/A 26 - 905378 905377 27 N/A 28 N/A 29 - 30 N/A 31 N/A 32 N/A 33 N/A 34 N/A 35 N/A 36 N/A 37 N/A 38 N/A 39 N/A 40 11680704 1 1 4 4 1 4 4 2 2 2 2 2 5 4 5 4 Qty. 6" Thru 8" Trolley Beam Flange Width Alignment Bar. 4" Thru 8" Trolley Beam Flange Width Cross Shaft. 8 1/8" Thru 14" Trolley Beam Flange Width Alignment Bar. 25' Lift Model Drum Side. M10 Lockwasher. M10 Hex Head Bolt. No. 16. 5/16" Traverse Motor (Specify HP. 55 FPM Traverse Reducer. 3/8"-16 Lockwasher. Nos. Frequency. 15. 18) Plain Wheel Assembly Pair (Incl. Ref. 25' Lift Model Traverse Drive Side. M10 Threaded Rod. 3/8 Locknut. M10 Lockwasher. 14 1/8" Thru 20" Trolley Beam Flange Width Torque Arm Traverse Reducer Traverse Reducer. Req’d 44934411 44934412 1 - N/A N/A 2 - N/A N/A 3 - N/A N/A 4 - 5 - 23387301 23387302 23387303 6 N/A 7 N/A 8 N/A 9 - N/A N/A N/A 10 N/A 11 N/A 1 1 1 1 2 3 4 4 2 12 4 . 13. 3/8 Plain Hex Nut. 18) Trolley Frame Side Drum Side. Ref. Voltage. 16. M20 (continued on next page) Page 38 Qty. of Speeds."B" Frame: Trolley Frame and Drive Components for Figure 9-3. Frequency. Part Number Description Internal Retaining Ring External Retaining Ring External Retaining Ring Ball Bearing w/Retaining Ring Flat Washer Traverse Pinion Key Set Screw. 40' Lift Model Hoist /Trolley Controls (Specify HP. No. 12. 25' Lift Model Counterweight. Voltage. Part Number Description Geared Wheel Assembly Pair (Incl. M20 Threaded Rod. No. 14 1/8" Thru 20" Trolley Beam Flange Width Plain Hex Nut. M16 Lockwasher. Options) Hex Head Bolt. 12. 5/16"-18 Lockwasher. No. 17. 17. 8 1/8" Thru 14" Trolley Beam Flange Width Cross Shaft. Ref. Ref. M6 Traverse Cross Shaft Cross Shaft. 3/8" Socket Head Cap Screw. 75 FPM Socket Head Cap Screw. 15. 3/8 Bumper (Optional) "C" Frame: Trolley Frame and Drive Components for Figure 9-3. 6" Thru 8" Trolley Beam Flange Width Threaded Rod. 14. of Speeds. 40' Lift Model Counterweight Plate Counterweight. 14 1/8" Thru 20" Trolley Beam Flange Width Key Plate Socket Head Cap Screw. 3/8" Traverse Motor (Specify HP. 14. Frequency. 3/8" Socket Head Cap Screw. 16. Voltage."C" Frame: Trolley Frame and Drive Components for Figure 9-3. 12. M10 Lockwasher. 40' Lift Model Hoist /Trolley Controls (Specify HP. 6" Thru 8" Trolley Beam Flange Width Cross Shaft. 18) Plain Wheel Assembly Pair (Incl. 3/8 Bumper (Optional) Qty. of Speeds. Req’d 4 2 2 8 4 4 4 2 2 2 2 4 1 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 - N/A N/A N/A 25 N/A 26 - 33292001 33292002 27 N/A 28 N/A 29 - 30 N/A 31 N/A 32 N/A 33 N/A 34 N/A 35 N/A 36 N/A 37 N/A 38 N/A 39 N/A 40 11680701 1 1 4 4 1 4 4 3 3 3 2 2 5 8 5 4 "D" Frame: Trolley Frame and Drive Components for Figure 9-3. 16. 40' Lift Model Counterweight Plate Counterweight. M16 Lockwasher. of Speeds. 17. 80 FPM Hex Head Bolt. Ref. 3/8 Locknut. M10 Flat Washer. M16 Hex Head Bolt. 25' Lift Model Counterweight. No. Nos. M16 Lockwasher. Part Number Description Wheel Axle Plain Trolley Wheel Geared Trolley Wheel Ball Bearing Internal Retaining Ring External Retaining Ring External Retaining Ring Ball Bearing w/Retaining Ring Flat Washer Traverse Pinion Key Set Screw. 3/8"-16 Lockwasher. M10 Hex Head Bolt. Frequency. 8 1/8" Thru 14" Trolley Beam Flange Width Cross Shaft. No. Options) Alignment Bar Alignment Bar. 12. 8" Thru 14" Trolley Beam Flange Width Alignment Bar. 14 1/8" Thru 20" Trolley Beam Flange Width Torque Arm Traverse Reducer Traverse Reducer. 25' Lift Model Traverse Drive Side. No. Req’d 44937911 44937912 1 - N/A N/A 2 - N/A N/A 3 - N/A N/A 4 - 5 - 23392502 23392503 6 N/A 7 N/A 8 N/A 1 1 1 1 2 3 4 4 . Ref. Nos. 18) Trolley Frame Side Drum Side. 15. 40' Lift Model Trolley Frame Side Traverse Drive Side. 3/8"-16 Lockwasher. Part Number Description Geared Wheel Assembly Pair (Incl. No. Ref. 17. Voltage. M6 Traverse Cross Shaft Cross Shaft. M16 (continued on next page) Page 39 Qty. Ref. 3/8 Plain Hex Nut. 13. 25' Lift Model Drum Side. 50 FPM Traverse Reducer. 15. Options) Hex Head Bolt. 14 1/8" Thru 20" Trolley Beam Flange Width Plain Hex Nut. 80 FPM Socket Head Cap Screw. M10 Flat Washer. M20 Lockwasher. 50 FPM Traverse Reducer. 14 1/8" Thru 20" Trolley Beam Flange Width Torque Arm Traverse Reducer Traverse Reducer. 8" Thru 14" Trolley Beam Flange Width Threaded Rod. Frequency. 3/8"-16 Lockwasher. 3/8"-16 Lockwasher. 3/8"-16 Traverse Motor (Specify HP. M20 Hex Head Bolt. M6 Traverse Cross Shaft Cross Shaft."D" Frame: Trolley Frame and Drive Components for Figure 9-3. 8" Thru 14" Trolley Beam Flange Width Cross Shaft. of Speeds. No. Part Number Description Threaded Rod. Options) Hex Head Bolt. M10 Hex Head Bolt. Ref. 3/8 Locknut. No. M20 Lockwasher. 3/8 Bumper (Optional) Qty. M20 Wheel Axle Plain Trolley Wheel Geared Trolley Wheel Ball Bearing Internal Retaining Ring External Retaining Ring External Retaining Ring Ball Bearing w/Retaining Ring Flat Washer Traverse Pinion Key Set Screw. M20 Threaded Rod. 3/8 Plain Hex Nut. M10 Lockwasher. Voltage. 3/8" Socket Head Cap Screw. Req’d 2 12 4 4 2 2 8 4 4 4 2 2 2 2 4 1 1 1 4 4 1 4 4 2 2 2 2 2 5 4 5 4 9 - N/A N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 - N/A N/A 25 N/A 26 - 33293801 33293802 27 N/A 28 N/A 29 - 30 N/A 31 N/A 32 N/A 33 N/A 34 N/A 35 N/A 36 N/A 37 N/A 38 N/A 39 N/A 40 11680701 Notes Page 40 . Nos. 14) Hook Latch Kit (Not shown) Hook Assembly (Incl. 3. 13. Lower Block Assembly "B" Frame: Lower Block Components for Figure 9-4. Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number Description 44931901C 33290601 4X1309 23380691 N/A N/A N/A N/A N/A N/A N/A 33290902 N/A N/A N/A N/A N/A N/A N/A 33290912 23382810 23382801 N/A N/A Lower Block Assembly (Excludes Ref. Ref. No. M6 Locknut. 2. M8 Socket Head Cap Screw. Nos. 17 & 18) Sheave Assembly (Incl. Req’d 1 1 1 1 1 1 2 2 2 4 2 2 2 4 2 2 2 2 2 6 6 Page 41 . 4) Trunnion Crosshead Hook & Nut Assembly Thrust Bearing Roll Pin Sheave Pin Spacer Tube Lower Block Strap Inner Sheave Cover Flat Washer. Nos.Figure 9-4. M6 Qty. 12. M8 Locknut. Ref. M8 Rope Sheave Ball Bearing Internal Retaining Ring External Retaining Ring Outer Sheave Cover 5t Capacity Label SHAW-BOX Brand Label Socket Head Cap Screw. 3. Nos. M8 Qty. Nos. Req’d 1 1 1 1 1 1 2 2 2 4 2 2 2 4 2 2 2 2 2 6 6 . No. 3. 14) Hook Latch Kit (Not shown) Hook Assembly (Incl. 13. 17 & 18) Sheave Assembly (Incl. M12 Rope Sheave Ball Bearing Internal Retaining Ring External Retaining Ring Outer Sheave Cover 15t Capacity Label SHAW-BOX Brand Label Socket Head Cap Screw. Req’d 1 1 44934901C 44934901C 33292101 4X1315 23389291 1 N/A 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 33291802 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 N/A 15 N/A 16 33291812 17 - 23282812 23382811 18 23382801 19 N/A 20 N/A 1 1 1 1 1 2 2 2 4 2 2 2 4 2 2 2 2 2 6 6 "D" Frame: Lower Block Components for Figure 9-4. 12. M12 Socket Head Cap Screw. M8 Locknut. Part Number Description 10t Lower Block Assembly (Excludes Ref. M8 Locknut. Nos. M12 Rope Sheave Ball Bearing Internal Retaining Ring External Retaining Ring Outer Sheave Cover Capacity Label 10t Capacity Plate 7. 17 & 18) 7. No.5t Capacity Plate SHAW-BOX Brand Label Socket Head Cap Screw."C" Frame: Lower Block Components for Figure 9-4. M12 Threaded Stud. Ref. Nos. Ref. Nos. Ref.5t Lower Block Assembly (Excludes Ref. 2. M12 Locknut. M8 Qty. Nos. 17 & 18) Sheave Assembly (Incl. Ref. 4) Trunnion Crosshead Hook & Nut Assembly Thrust Bearing Roll Pin Sheave Pin Spacer Tube Lower Block Strap Inner Sheave Cover Flat Washer. M12 Locknut. 14) Hook Latch Kit (Not shown) Hook Assembly (Incl. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Page 42 Part Number Description 44936901C 33293701 4X1322 23394091 N/A N/A N/A N/A N/A N/A N/A 33292801 N/A N/A N/A N/A N/A N/A N/A 33292811 23391525 23391501 N/A N/A Lower Block Assembly (Excludes Ref. 12. Ref. Ref. 4) Trunnion Crosshead Hook & Nut Assembly Thrust Bearing Roll Pin Sheave Pin Spacer Tube Lower Block Strap Inner Sheave Cover Flat Washer. 2. 13. Nos. 12) Upper Block Yoke Yoke Pin Yoke Spacer (Not Required on "C" Frame) External Retaining Ring Locknut. 10. M6 Hex Head Bolt. Ref.Figure 9-5. M6 Hex Head Bolt. 11. Req’d 1 1 1 0 2 2 2 1 2 2 1 2 1 Page 43 . Ref. M6 Sheave Pin External Retaining Ring Spacer Washer Internal Retaining Ring Sealed Ball Bearing Rope Sheave Qty. 12) Upper Block Yoke Yoke Pin Yoke Spacer ("B" Frame Only) External Retaining Ring Locknut. No. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number Description 44934601C 33292101 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A "C" Frame Hoist Upper Block Assembly Sheave Assembly (Incl. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number Description 44932701 33290601 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A "B" Frame Hoist Upper Block Assembly Sheave Assembly (Incl. Ref. Nos. Req’d 1 1 1 1 2 2 2 1 2 2 1 2 1 "C" Frame: Upper Block Components for Figure 9-5. 11. Upper Block Assembly "B" Frame: Upper Block Components for Figure 9-5. No. Ref. M6 Sheave Pin External Retaining Ring Spacer Washer Internal Retaining Ring Sealed Ball Bearing Rope Sheave Qty. 10. Nos. Nos. Req’d 1 1 1 0 2 2 2 1 2 2 1 2 1 Notes Page 44 . Ref. M10 Sheave Pin External Retaining Ring Spacer Washer Internal Retaining Ring Sealed Ball Bearing Rope Sheave Qty. Ref. 1 2 3 4 5 6 7 8 9 10 11 12 Part Number Description 44936601C 33293701 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A "D" Frame Hoist Upper Block Assembly Sheave Assembly (Incl. 10. 11. 12) Upper Block Yoke Yoke Pin Yoke Spacer (Not Required on "D" Frame) External Retaining Ring Locknut."D" Frame: Upper Block Components for Figure 9-5. No. M10 Hex Head Bolt. 25' Lift Model. 40' Lift Model. M5 Plain Hex Nut. #10 (Optional) Qty. M8 Thread Belleville Spring Washer Hex Head Bolt. Nos.Optional Equipment Limit Switch Bracket (Optional) Limit Switch (Optional) Limit Switch Hub (Optional) Actuator Rod (Optional) Pan Head Screw. M6 Locknut. 9mm Socket Head Shoulder Bolt. No. M5 Limit Switch Socket Head Cap Screw. #10 (Optional) Lockwasher. 9mm Rope Assembly. #10 (Optional) Socket Head Cap Screw. Wire Rope Dead End Assembly with Limit Switch ("B" & "C" Frame) "B" Frame: Wire Rope Dead End Assembly Components for Figure 9-6a.Figure 9-6a.25) Dead End Yoke Yoke Pin External Retaining Ring Overload Beam Dead End Pin Spacer External Retaining Ring Overload Spring Base Hex Head Bolt. Ref. 19 . Ref. Req’d 1 1 1 2 1 1 2 2 1 2 2 1 1 4 1 1 1 2 2 1 1 1 1 1 2 2 2 Page 45 44932801C 1 N/A 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 - 23383601 23383602 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 33290501C 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 N/A 25 N/A . M5 Hi-Collar Lockwasher "B" Frame Block Operated Limit Switch . 11. M6 Wire Rope and Swaged End Assembly Rope Assembly. Part Number Description "B" Frame Hoist Rope and Dead End Assembly (Excl. M5 Hi-Collar Lockwasher "C" Frame Block Operated Limit Switch . #10 (Optional) Socket Head Cap Screw. 25' Lift Model."C" Frame: Wire Rope Dead End Assembly Components for Figure 9-6a. #10 (Optional) Lockwasher. M10 Wire Rope and Swaged End Assembly Rope Assembly. Ref.25) Dead End Yoke Yoke Pin External Retaining Ring Overload Beam Dead End Pin Spacer External Retaining Ring Overload Spring Base Hex Head Bolt. Ref. M5 Limit Switch Socket Head Cap Screw. No. 12mm Socket Head Shoulder Bolt. M8 Thread Belleville Spring Washer Hex Head Bolt. Req’d 1 1 1 2 1 1 2 2 1 2 2 1 1 6 1 1 1 2 2 1 1 1 1 1 2 2 2 44934701C 1 N/A 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 - 23386501 23386502 12 N/A 13 N/A 14 N/A 15 N/A 16 N/A 17 N/A 18 N/A 33290501C 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A 24 N/A 25 N/A Notes Page 46 . 12mm Rope Assembly. 19 . M5 Plain Hex Nut. Nos. M10 Locknut. Part Number Description "C" Frame Hoist Rope and Dead End Assembly (Excl. 11. 40' Lift Model.Optional Equipment Limit Switch Bracket (Optional) Limit Switch (Optional) Limit Switch Hub (Optional) Actuator Rod (Optional) Pan Head Screw. #10 (Optional) Qty. Part Number Description "D" Frame Hoist Rope and Dead End Assembly (Excl. 25' Lift Model. No. M12 Belleville Spring Washer Overload Plate Locknut. M12 Flat Washer. Ref. #10 (Optional) Qty. Req’d 1 1 1 1 1 2 2 1 3 4 1 1 1 2 1 1 2 2 1 1 1 1 2 2 2 Page 47 44937001C 1 N/A 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 N/A 8 N/A 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 - 23393901 23393902 15 N/A 16 N/A 17 N/A 33290504C 18 N/A 19 N/A 20 N/A 21 N/A 22 N/A 23 N/A . Wire Rope Dead End Assembly with Limit Switch ("D" Frame) "D" Frame: Wire Rope Dead End Assembly Components for Figure 9-6b. #10 (Optional) Pan Head Screw.Optional Equipment Limit Switch (Optional) Limit Switch Hub (Optional) Actuator Rod (Optional) Socket Head Cap Screw. M5 "D" Frame Block Operated Limit Switch .Figure 9-6b. Ref. Nos. 14) Dead End Yoke Yoke Pin External Retaining Ring Dead End Pin Spacer External Retaining Ring Hex Head Bolt. M5 Wire Rope and Swaged End Assembly Rope Assembly. 15mm Limit Switch Socket Head Cap Screw. M5 Plain Hex Nut. M12 Hex Head Bolt. 40' Lift Model. 15mm Rope Assembly. M5 Hi-Collar Lockwasher. #10 (Optional) Lockwasher. Ref. 1 2 3 4 5 Part Number Description 44931801C N/A N/A N/A N/A N/A "B" Frame Rope Guide Assembly Rope Guide Body Plastic Shroud Socket Head Shoulder Bolt. No. M6 Thread Compression Spring Extension Spring Qty. Ref. Rope Guide Assembly ("B" & "C" Frame) "B" Frame: Rope Guide Components for Figure 9-7a.Figure 9-7a. 1 2 3 4 5 Part Number Description 44933801C N/A N/A N/A N/A N/A "C" Frame Rope Guide Assembly Rope Guide Body Plastic Shroud Socket Head Shoulder Bolt. No. Req’d 1 1 1 2 2 1 "C" Frame: Rope Guide Components for Figure 9-7a. M6 Thread Compression Spring Extension Spring Qty. Req’d 1 1 1 2 2 1 Page 48 . M10 Locknut. M10 Qty. 3/8" Hex Head Bolt. Rope Guide Assembly "D" Frame: Rope Guide Components for Figure 9-7b. Req’d 1 1 2 2 4 2 2 2 Page 49 . Ref.Figure 9-7b. No. 1 2 3 4 5 6 7 Part Number Description 33293401C N/A N/A N/A N/A N/A N/A N/A "D" Frame Rope Guide Assembly Rope Guide Body Hub Bushing Guide Roller Roller Bushing Washer. Req’d 1 1 1 2 1 1 1 1 1 1 1 1 3 1 3 7 1 1 1 4 2 3 33313851 4 BRAKE 5 FAN 6 KIT 7 33313852 BRAKE HUB KIT 33313853 HARD- WARE KIT N/A N/A 33313855 SHROUD KIT 8 9 10 11 12 13 14 15 16 17 18 19 Page 50 . Ref. 1 Part Number Description 33313849 33313850 Complete Brake Assembly (Includes Ref.Order Complete Brake Fan Shroud Bolts (Fan Shroud) Qty.17 & P/N 33313853) Brake Friction Disc Fan External Retaining Rings (Fan Hub) External Retaining Ring (Fan) Fan Hub Key (Fan Hub) Key (Fan) External Retaining Ring (Brake Hub) Spacer (Brake Hub) Key (Brake Hub) Brake Hub Hollow Core Bolts O-Ring Bolts (Brake Mounting) Compression Springs Magnet Body . Standard Hoist Motor Brake (Except 33327303) "B" Frame: Hoist Brake Components for Figure 9-8a. Nos.16. No. 1.11.Order Complete Brake Armature Plate .Figure 9-8a. 18 thru 27) Spring Brake Adjuster Braking Torque Adjusting Lockout Air Gap Adjusting Nut Locknut Brake Disc Brake Moving Element Brake Coil Brake Cover Cover Retaining Nut Qty. Part Number Description 33327349 Complete Brake Assembly (Includes Ref. Nos. Req’d 1 3 3 3 3 3 1 1 1 1 1 18 33327350 19 20 Brake 21 Adjuster 22 Set 33327351 33327352 33327353 33327354 33327355 23 24 25 26 27 Page 51 .Figure 9-8b. Standard Hoist Motor Brake (7½ hp Motor 33327303) "B" Frame: Hoist Brake Components for Figure 9-8b. Ref. No. 1 Part Number Description 33263249 33263250 Complete Brake Assembly (Includes Ref. Ref. Req’d 1 1 1 2 1 1 1 1 1 1 1 1 3 1 3 7 1 1 1 4 2 3 33263251 4 BRAKE 5 FAN 6 KIT 7 33263252 BRAKE HUB KIT 33263253 HARD- WARE KIT N/A N/A 33263255 SHROUD KIT 8 9 10 11 12 13 14 15 16 17 18 19 Page 52 .Order Complete Brake Armature Plate . Nos.16. 1.Order Complete Brake Fan Shroud Bolts (Fan Shroud) Qty.11.Figure 9-8c.17 & P/N 33263253) Brake Friction Disc Fan External Retaining Rings (Fan Hub) External Retaining Ring (Fan) Fan Hub Key (Fan Hub) Key (Fan) External Retaining Ring (Brake Hub) Spacer (Brake Hub) Key (Brake Hub) Brake Hub Hollow Core Bolts O-Ring Bolts (Brake Mounting) Compression Springs Magnet Body . No. Standard Hoist Motor Brake "C" & "D" Frame: Hoist Brake Components for Figure 9-8c. Nos. 1 Part Number Description 33294049 33313850 Complete Brake Assembly (Includes Ref.Figure 9-9.Order Complete Brake Spacer Washers Fan Shroud Bolts (Fan Shroud) Qty. 18 & P/N 33294053) Brake Friction Disc Fan External Retaining Rings (Fan Hub) External Retaining Ring (Fan) Fan Hub Key (Fan Hub) Key (Fan) External Retaining Ring (Brake Hub) Spacer (Brake Hub) Key (Brake Hub) Stainless Steel Brake Hub Hollow Core Bolts O-Ring Bolts (Brake Mounting) Compression Springs Magnet Body . Req’d 1 1 1 2 1 1 1 1 1 1 1 1 3 1 3 7 1 1 1 4 1 4 2 3 33313851 4 BRAKE 5 FAN 6 KIT 7 33294052 BRAKE HUB KIT 33294053 HARD- WARE KIT N/A N/A N/A 11803105 33313855 SHROUD KIT 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Page 53 .Order Complete Brake Stainless Steel Friction Disc .17. No.16.Order Complete Brake Stainless Steel Armature Plate . Ref. 1.11. Outdoor Service Hoist Motor Brake "B" Frame: Hoist Brake Components for Figure 9-9. Req’d 1 1 1 2 1 1 1 1 1 1 1 1 3 1 3 7 1 1 1 4 1 4 2 3 33263251 4 BRAKE 5 FAN 6 KIT 7 33294152 BRAKE HUB KIT 33294153 HARD- WARE KIT N/A N/A N/A 11803106 33263255 SHROUD KIT 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Page 54 .11.Figure 9-9. Ref. 18 & P/N 33294153) Brake Friction Disc Fan External Retaining Rings (Fan Hub) External Retaining Ring (Fan) Fan Hub Key (Fan Hub) Key (Fan) External Retaining Ring (Brake Hub) Spacer (Brake Hub) Key (Brake Hub) Stainless Steel Brake Hub Hollow Core Bolts O-Ring Bolts (Brake Mounting) Compression Springs Magnet Body . 1 Part Number Description 33294149 33263250 Complete Brake Assembly (Includes Ref. Outdoor Service Hoist Motor Brake "C" & "D" Frame: Hoist Brake Components for Figure 9-9. Nos. No.Order Complete Brake Spacer Washers Fan Shroud Bolts (Fan Shroud) Qty.Order Complete Brake Stainless Steel Armature Plate . 1.Order Complete Brake Stainless Steel Friction Disc .16.17. Notes . Catalog Number. In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages. Parts for your hoist are available from your local authorized SHAW-BOX repair station. point of delivery or at Seller’s authorized service station nearest Buyer or (ii) refund an equitable portion of the purchase price. construction or start-up responsibility. when performed. will be of good quality and will be free from defects in material and workmanship.o. All claims for defective products or parts when Seller specifically assumes installation. or if Seller’s products have been dismantled prior to submission to Seller for warranty inspection. SHAW-BOX ® . construction or start-up responsibility and all claims for defective work must be made in writing immediately upon discovery and in any event. Motor Horsepower. strict liability or otherwise. INCLUDING. IMPLIED AND STATUTORY. and its work (including installation. It is suggested that the following parts be purchased for your hoist as spares for future use. within one (1) year from completion of the applicable work by Seller. part or work at either the original f. The foregoing is Seller’s only obligation and Buyer’s exclusive remedy for breach of warranty and is Buyer’s exclusive remedy hereunder by way of breach of contract. will meet applicable specifications. Seller shall at its option either (i) repair or replace its product. Upon Buyer’s submission of a claim as provided above and its substantiation. This warranty is contingent upon Buyer’s proper maintenance and care of Seller’s products. construction and start-up). WITHOUT LIMITATION. however. when shipped. within one (1) year from shipment of the applicable item unless Seller specifically assumes installation. Defective items must be held for Seller’s inspection and returned to the original f. MI 49443-0769 Phone: 800 742-9269 Fax: 800 742-9270 WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A. write: YaleLift-Tech 414 West Broadway Avenue P. EXPRESS. Seller warrants that its products and parts.O. all claims for defective products and parts made in writing no later than eighteen (18) months after shipment. C. provided.o. Frequency and Rated Load of Hoist on which the parts are to be used. point upon request. Any action for breach of this agreement must be commenced within one (1) year after the cause of action has accrued. B. Box 769 Muskegon. Seller reserves the right to void warranty in event of Buyer’s use of inappropriate materials in the course of repair or maintenance. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. D. All claims for defective products or parts under this warranty must be made in writing immediately upon discovery and in any event. require replacement under normal wear conditions. Phase. Voltage. For the location of your nearest repair station. One Brake Friction Disc One Brake Control Module One Brake Hardware Kit One Set of Contactors One Transformer One Wire Rope Assembly Note: When ordering parts always furnish Hoist Serial Number.Recommended Spare Parts Certain parts of your hoist will. tort.b. THE ‘FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER. in time.b. and does not extend to normal wear and tear.